Buell XB 2010 Service Manual

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2010 Buell XB Models Service Manual

99490-10Y

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Summary of Contents for Buell XB 2010

Page 2 IMPORTANT NOTICE Buell motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture. To maintain the safety, dependability, and emission and noise control performance, it is essential that the procedures, specifications and service instructions in this manual are followed.
Page 4 Blank Text Here...
Page 5 READER COMMENTS Blank Text Here The Buell Motorcycle Company maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we need user feedback - your critical evaluation of this manual. Please comment on the completeness, accuracy, organization, usability, and readability of this manual.
Page 6 NOTES...
Page 7 First, it will acquaint the user with the construction of the To avoid unnecessary disassembly, carefully read all rel- Buell product and assist in the performance of basic mainten- ance and repair. Secondly, it will introduce to the professional ative service information before repair work is started.
Page 8 Accordingly, anyone who uses a service H-D MICHIGAN, INC. TRADEMARK procedure or tool which is not recommended by Buell Motor- INFORMATION cycle Company must first thoroughly satisfy himself that neither his nor the operator's safety will be jeopardized as a result.
Page 9: Table Of Contents
Storage Units...............1-6 Bleeding Rear Brake..........1-32 1.3 FUEL AND OIL Brake Pedal Adjustment...........1-32 Brake Pad Thickness............1-33 Fuel..................1-7 Brake Rotor Thickness.............1-34 Gasoline Blends: Buell Models...........1-7 Brake Pad Replacement...........1-34 Engine Lubrication..............1-7 Front Pad Removal............1-34 Winter Lubrication..............1-8 Front Pad Installation..........1-34 Rear Pad Removal............1-35 1.4 BULB REQUIREMENTS Rear Pad Installation..........1-35...
Page 10 TABLE OF CONTENTS Using a Battery Charger..........1-40 Clutch Chatters............1-53 Battery Installation and Connection........1-41 Clutch................1-53 Storage................1-42 Slips................1-53 Maintaining Charge............1-42 Drags or Does Not Release........1-53 Chatters..............1-53 1.17 STEERING HEAD BEARINGS Chassis................1-53 Irregular/Inadequate Brake Action......1-53 General................1-44 Handling Irregularities..........1-53 Inspection.................1-44 Suspension...............1-54 Determining Proper Resistance........1-44 CHASSIS 1.18 FRONT FORK OIL REPLACEMENT General................1-45...
Page 11 TABLE OF CONTENTS 2.7 TIRES 2.11 BRAKE PEDAL General................2-42 Removal................2-66 Specifications..............2-42 Installation................2-66 Tire Sizes..............2-42 2.12 REAR BRAKE MASTER CYLINDER Rim Sizes..............2-42 Dismounting..............2-43 Removal: Firebolt/Lightning..........2-67 Cleaning and Inspection...........2-43 Removal: Ulysses.............2-68 Mounting................2-44 Disassembly..............2-70 Wheel and Valve Stems..........2-44 Cleaning and Inspection...........2-70 Using the Tire Machine..........2-44 Assembly................2-70 Inflate Tire..............2-46 Installation: Firebolt/Lightning...........2-71...
Page 12 TABLE OF CONTENTS Installation: Firebolt............2-90 2.26 HEADLAMP ASSEMBLY AND Removal: Lightning/Ulysses..........2-91 SUPPORT BRACKET Installation: Lightning/Ulysses..........2-91 Removal: Firebolt............2-117 2.18 STEERING HEAD BEARINGS Disassembly: Firebolt.............2-117 Assembly: Firebolt............2-117 Removal................2-93 Installation: Firebolt............2-118 Installation................2-93 Removal: Lightning/Ulysses...........2-119 2.19 SWINGARM AND BRACE Disassembly: Lightning/Ulysses........2-121 Assembly: Lightning/Ulysses..........2-121 General................2-96 Installation: Lightning/Ulysses........2-122 Brace................2-96 Removal..............2-96...
Page 13 TABLE OF CONTENTS 2.35 HEEL GUARD AND FOOTPEG 2.45 TRUNK AND BATTERY PAN: ULYSSES MOUNTS: ULYSSES MODELS MODELS Rider Footpegs...............2-135 Disassembly Trunk and Battery Pan.......2-158 Footpeg Removal............2-135 Assembly/Trunk Pan and Battery Pan......2-158 Footpeg Installation..........2-135 2.46 SIDESTAND Passenger Footpegs............2-135 Footpeg Removal............2-135 General................2-159 Footpeg Installation..........2-135 Removal.................2-159...
Page 14 TABLE OF CONTENTS Removal..............2-175 3.7 CYLINDER HEAD Installation...............2-175 Removal................3-35 Removal: Ulysses Models..........2-176 Rocker Box Assemblies..........3-35 Installation: Ulysses Models...........2-176 Cylinder Head Assemblies........3-37 Pillion Lock Removal: XB12R.........2-177 Disassembly..............3-37 Pillion Lock Installation: XB12R........2-178 Cleaning and Inspection...........3-40 Cylinder Heads............3-40 2.53 TRIPLE TAIL: ULYSSES MODELS Rocker Arm Assemblies..........3-40 General................2-179 Valves................3-41...
Page 15 TABLE OF CONTENTS Reed Valve Replacement..........3-74 4.5 THROTTLE POSITION SENSOR (TPS) Removal................4-10 3.16 HYDRAULIC LIFTERS Installation................4-10 General................3-76 Removal................3-76 4.6 IGNITION COIL Cleaning and Inspection...........3-76 Removal................4-11 Installation................3-77 Installation................4-11 3.17 GEARCASE AND CAM GEARS 4.7 OXYGEN SENSORS (O2) General................3-78 General................4-12 Removal and Disassembly..........3-79 Removal................4-12 Cleaning and Inspection...........3-79 Installation................4-13...
Page 16 TABLE OF CONTENTS Fuel Injectors.............4-30 5.3 PRIMARY COVER Installation................4-30 Removal................5-4 Injector Leak Testing..........4-31 Primary Chain Adjuster Replacement........5-5 Installation................5-6 4.16 FUEL PRESSURE SENSOR Replacement..............4-32 5.4 CLUTCH RELEASE MECHANISM Removal..............4-32 Disassembly...............5-8 Installation..............4-32 Cleaning and Inspection.............5-8 Assembly................5-9 4.17 FUEL PRESSURE TEST Inspection.................4-33 5.5 CLUTCH General................5-10 4.18 INTAKE LEAK TEST Removal................5-12...
Page 17 TABLE OF CONTENTS Main Drive Gear Seal..........5-45 Removal................6-13 Inspection.................6-13 5.13 TRANSMISSION RIGHT CASE Installation................6-13 BEARINGS 6.5 CHARGING SYSTEM Removal................5-47 General................6-15 Countershaft Needle Bearing........5-47 Alternator..............6-15 Shifter Drum Bushing..........5-47 Voltage Regulator............6-15 Installation................5-47 Countershaft Needle Bearing........5-47 6.6 BATTERY CABLES Shifter Drum Bushing..........5-47 Removal................6-18 5.14 TRANSMISSION LEFT CASE Installation................6-18 BEARINGS...
Page 18 TABLE OF CONTENTS 6.13 TURN SIGNAL FLASHER Removal and Disassembly........6-59 Assembly and Installation..........6-59 Removal................6-37 Installation................6-37 6.20 MAIN FUSE AND FUSES 6.14 FRONT TURN SIGNALS General................6-60 Fuses................6-60 Bulbs................6-39 Main Fuse..............6-60 Repair................6-39 Connections and Wire Routing........6-39 6.21 NEUTRAL INDICATOR SWITCH Firebolt................6-39 General................6-63 Removal..............6-39 Testing................6-63 Installation..............6-39...
Page 19 TABLE OF CONTENTS 6.30 AUXILIARY POWER OUTLETS: A.7 DEUTSCH MINI TERMINAL REPAIR ULYSSES MODELS Deutsch Mini Terminal Crimps.........A-15 Preparing Wire Leads for Crimping......A-15 General................6-95 Crimping a Mini Terminal to Wire Lead.....A-15 Accessory Load Test............6-95 Inspecting Crimps.............A-15 APPENDIX A CONNECTOR REPAIR A.8 PACKARD 150 METRI-PACK CONNECTORS A.1 AMP MULTILOCK CONNECTORS...
Page 20 TABLE OF CONTENTS C.2 FLUID CONVERSION Active Intake System..........E-1 Diagnostic Notes............E-1 United States System............C-2 Verify Settings..............E-1 Metric System..............C-2 WOT Check................E-1 British Imperial System............C-2 Cable..................E-1 Adjustment..............E-1 C.3 TORQUE CONVERSION Throttle Stop Screw............E-3 United States System............C-3 Removal................E-4 Metric System..............C-3 Installation................E-5 APPENDIX D HOSE AND WIRE APPENDIX F GLOSSARY ROUTING F.1 GLOSSARY...
Page 21 TABLE OF CONTENTS SUBJECT..........................PAGE NO. 1.1 FASTENER TORQUE VALUES....................1-1 1.2 GENERAL..........................1-3 1.3 FUEL AND OIL..........................1-7 1.4 BULB REQUIREMENTS......................1-9 1.5 MAINTENANCE SCHEDULE....................1-10 1.6 ENGINE OIL AND FILTER......................1-11 1.7 AIR CLEANER AND EXHAUST SYSTEM................1-14 1.8 TIRES AND WHEELS......................1-17 1.9 CLUTCH/TRANSMISSION/PRIMARY FLUID.................1-19 1.10 PRIMARY CHAIN........................1-22 1.11 DRIVE BELT MAINTENANCE....................1-24 1.12 THROTTLE CABLE.......................1-27 1.13 INTERACTIVE EXHAUST CABLE..................1-28...
Page 22 NOTES...
Page 23: Fastener Torque Values
HOME FASTENER TORQUE VALUES FASTENER TORQUE VALUES IN THIS CHAPTER The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE NOTES Battery terminal fastener 60-70 in-lbs 6.8-7.9 Nm 1.10 PRIMARY CHAIN, Inspection Battery terminal fastener 60-70 in-lbs 6.8-7.9 Nm 1.16 BATTERY MAINTENANCE, Battery Installa-...
Page 24 HOME FASTENER TORQUE VALUE NOTES Rear brake line assembly fastener 36-60 in-lbs 4-6.8 Nm 1.14 BRAKE SYSTEM MAINTENANCE, Brake Pad Replacement Rear caliper bleeder valve 36-60 in-lbs 4-6.8 Nm 1.14 BRAKE SYSTEM MAINTENANCE, Bleeding Brakes Rear caliper pin hanger 132-168 in-lbs 14.9-19 Nm 1.14 BRAKE SYSTEM MAINTENANCE, Brake Pad Replacement...
Page 25: General
HOME GENERAL SERVICING A NEW MOTORCYCLE Safety Safety is always the most important consideration when per- forming any job. Be sure you have a complete understanding of the task to be performed. Use common sense. Use the Perform the service and maintenance operations as proper tools.
Page 26: Disassembly And Assembly
HOME Disassembly and Assembly Wiring, Hoses and Lines Always assemble or disassemble one part at a time. Do not Hoses, clamps, electrical wiring, electrical switches or fuel lines work on two assemblies simultaneously. Be sure to make all if they do not meet specifications. necessary adjustments.
Page 27: Gears
HOME Cover bearings with a clean shop towel and allow to air dry. Gears Do not spin bearings while they are drying. Never use com- Always check gears for damaged or worn teeth. pressed air to dry bearings. Remove burrs and rough spots with a honing stone or crocus When dry, coat bearings with clean oil.
Page 28: Punches/Chisels
HOME Punches/Chisels Ratchets and Handles Never use a punch or chisel with a chipped or mush- Periodically clean and lubricate ratchet mechanisms with roomed end. Dress mushroomed chisels and punches a light grade oil. Do not replace parts individually; ratchets with a grinder.
Page 29: Fuel And Oil
Pump Octane (R+M)/2 91 (95 RON) some lubricants interact chemically when mixed. Use of GASOLINE BLENDS: BUELL MODELS inferior lubricants can damage the engine. (00184a) Engine oil is a major factor in the performance and service life Your motorcycle was designed to get the best performance of the engine.
Page 30: Winter Lubrication
HOME Water vapor is a normal by-product of combustion in any WINTER LUBRICATION engine. During cold weather operation, some of the water vapor In colder climates, the engine oil should be changed often. If condenses to liquid form on the cool metal surfaces inside the motorcycle is used frequently for short trips, less than 15 mi engine.
Page 31: Bulb Requirements
HOME BULB REQUIREMENTS GENERAL Use the table to identify the bulb location and part number. Refer to Table 1-3. Table 1-3. Bulb Chart: 2010 XB Models BULBS BULBS WATTS AMPS PART REQUIRED NUMBER Headlamps Bulb (H3) (Firebolt) 4.58 68918-98 Bulb (H7) (Lightning/Ulysses) 4.58 Y0148.1AD Position lamp (Firebolt)
Page 32: Maintenance Schedule
Verify component and system func- tions NOTES: 1. Should be performed by an authorized Buell dealer, unless you have the proper tools, service data and are mechanically qualified. 2. Change brake fluid every two (2) years. 3. Inspect oil lines and brake system annually or at specified intervals, whichever comes first.
Page 33: Engine Oil And Filter
HOME ENGINE OIL AND FILTER Remove the oil level dipstick and visually check for oil in GENERAL the tank. An accurate reading of the engine oil level can only be taken If there is no oil in the tank, add oil in 6.8 fl oz (0.2 L) with the engine at normal operating temperature (hot check).
Page 34: Change Engine Oil And Filter
1. Oil filter 2. Oil pressure switch 3. Oil line fittings Figure 1-4. Oil Filter: Buell Models except Blast Fill Engine With Oil Inspect drain plug O-ring for tears or damage. Replace if required. Wipe any foreign material from drain plug.
Page 35: Clear Oil Cooler
HOME NOTE Blow out any debris from fins with compressed air from For ease of installation, apply a light film of clean engine oil to the inside of the oil cooler outward. Inspect cooler fins for the dipstick O-ring. debris or damage. Install dipstick into oil tank/swingarm fill hole.
Page 36: Air Cleaner And Exhaust System
HOME AIR CLEANER AND EXHAUST SYSTEM REMOVAL sm00376 Install air filter before running engine. Failure to do so can draw debris into the engine and could result in engine damage. (00207a) Check air filter element: Inspect at the 1000 mile (1600 km) service interval and at every 5000 mile (8000 km) service interval thereafter.
Page 37: Cleaning And Inspection
HOME sm00501 sm00503 Figure 1-8. Air Cleaner Cover Latches 1. Breather hoses (2) 2. Intake air sensor 3. Velocity stack sm00502 Figure 1-10. Air Cleaner Baseplate Assembly INSTALLATION Figure 1-11. Place filter element (1) on baseplate (2). Position air cleaner cover over baseplate. Make sure air filter remains correctly positioned.
Page 38: Exhaust System Leak Check
HOME EXHAUST SYSTEM LEAK CHECK sm00502 Check the exhaust system for leaks at every scheduled service interval as follows: Check entire exhaust system for loose or missing fasteners, broken pipe clamps or brackets, and obvious signs of leakage (carbon tracks at pipe joints, etc.). Check for loose or broken heat shields.
Page 39: Tires And Wheels
Do not inflate tire beyond maximum pressure as specified on sidewall. Over inflated tires can blow out, which could Use only Buell approved tires. See a Buell dealer. Using result in death or serious injury. (00027a) non-approved tires can adversely affect stability, which Check tire pressure and tread: could result in death or serious injury.
Page 40: Wheel Bearings
HOME WHEEL BEARINGS om00963 Using compressed air to "spin dry" bearings can cause bearing to fly apart, which could result in death or serious injury. (00505b) Check front and rear wheel bearings for wear: Every time a wheel is removed. When storing or removing the motorcycle for the season.
Page 41: Clutch/Transmission/Primary Fluid
HOME CLUTCH/TRANSMISSION/PRIMARY FLUID INSPECTION sm01388 Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative battery cable from battery. Figure 1-14. Remove three TORX screws with washers (1) from clutch inspection cover (2).
Page 42: Adjustment
HOME sm05323 Do not overfill the primary chaincase with lubricant. Overfilling can cause rough clutch engagement, incom- plete disengagement, clutch drag and/or difficulty in finding neutral at engine idle. (00199b) Make certain primary chaincase is filled with proper amount of lubricant with motorcycle upright. If under filled, transmission can be damaged during vehicle operation.
Page 43 HOME hook. Once the measurement has been attained you will sm00091 need to route the cable through the hook. Spring installs on outboard side of hex lockplate. Squeeze clutch hand lever to maximum limit three times. This sets the ball and ramp mechanism. Adjust as follows: Figure 1-20.
Page 44: Primary Chain
HOME PRIMARY CHAIN 1.10 INSPECTION sm00097 Figure 1-21. Measure primary chain tension through the inspection cover opening. Adjust primary chains not meeting vertical free play specifications. Disconnect battery negative (-) cable. Figure 1-21. Remove two fasteners with captive washers and primary chain inspection cover with gasket from primary cover.
Page 45 HOME Tighten locknut (1) to 20-25 ft-lbs (27.1-33.9 Nm). sm00096 1. Locknut 2. Adjusting fastener Figure 1-23. Chain Tension Adjusting Fastener (Typical) 2010 XB Service: Maintenance 1-23...
Page 46: Drive Belt Maintenance
HOME DRIVE BELT MAINTENANCE 1.11 result in belt failure and indicates worn transmission GENERAL sprocket teeth. Replace belt and transmission sprocket. The drive belt tension on a new belt will loosen after approxim- Signs of puncture or cracking at the base of the belt teeth. ately 1000 miles (1600 km).
Page 47 HOME Table 1-7. Potential Limits to Belt Drive Service Life CONDITION ROOT CAUSE REQUIRED ACTION Excessive edge wear Misalignment or bent drive structure Check structure (bad bearing, bent members, etc.). (mistracking) Bent or rough flange Repair flange/replace sprocket. Damage due to handling (pry on, etc.) Follow proper handling/installation procedure.
Page 48 HOME Table 1-7. Potential Limits to Belt Drive Service Life CONDITION ROOT CAUSE REQUIRED ACTION Belt breakage Excessive load/shock load Inspect/replace belt. Inform operator. Damage due to handling (pry-on, etc.) Follow proper handling/installation procedure. Debris in sprocket or belt Inspect/replace sprocket. Clean and protect drive.
Page 49: Throttle Cable
HOME THROTTLE CABLE 1.12 released. If this is not the case, turn adjuster on idle control THROTTLE CABLE ADJUSTMENT cable (shortening cable housing) until throttle control functions properly. Tighten cable adjuster lock on idle control cable. Recheck Be sure that steering is smooth and free without interfer- operation of throttle control.
Page 50: Interactive Exhaust Cable
HOME INTERACTIVE EXHAUST CABLE 1.13 is working properly. If you do not see the mark, verify ADJUSTMENT previous cable adjustment. Remove intake cover assembly. See 2.38 INTAKE DO NOT start vehicle in this mode. COVER. 10. Cycle the actuator to verify cable and valve operation: NOTES Hold the throttle wide open.
Page 51 HOME sm00506 sm00505 Figure 1-27. Checking For 1/8 in. (3.2 mm) Maximum Free Play In Either Direction For Proper Adjustment 1. Interactive exhaust cable 2. Frame lug Figure 1-28. Correct Cable Routing Behind Frame Lug (Typical) 2010 XB Service: Maintenance 1-29...
Page 52: Brake System Maintenance
HOME BRAKE SYSTEM MAINTENANCE 1.14 Inspect front and rear brake lines and replace as required: GENERAL Every 4 years. Check brake fluid level and condition: Inspect caliper and master cylinder seals and replace as When storing or removing the motorcycle for the season. required: Replace D.O.T.
Page 53: Bleeding Front Brake
HOME braking ability and lead to brake failure which could result in sm00485 death or serious injury. Bleeding Front Brake NOTE Hydraulic brake fluid bladder-type pressure equipment can be used to fill the brake master cylinder through the bleeder valve if master cylinder reservoir cover is removed to prevent pres- surization.
Page 54: Bleeding Rear Brake
HOME Install seat, if removed. Bleeding Rear Brake NOTE sm00488 Hydraulic brake fluid bladder-type pressure equipment can be used to fill the brake master cylinder through the bleeder valve if master cylinder reservoir cover is removed to prevent pres- surization. Figure 1-32.
Page 55: Brake Pad Thickness
HOME below the extruded nut (1) in the clevis by at least one full sm00490 thread. This is the rod minimum engagement (4). Also, there should be a minimum of 0.030 in. (0.8 mm) between brake rod end and brake pedal. Threaded rod should not be adjusted to the point of con- tacting brake pedal.
Page 56: Brake Rotor Thickness
HOME BRAKE ROTOR THICKNESS sm00493 Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d) Figure 1-37 Figure 1-38.
Page 57: Rear Pad Removal
HOME Figure 1-39. Install pin hanger (2) making sure it Rear Pad Installation engages hole on both pads and spring clip. Remove rear master cylinder reservoir cover. Rotate caliper clockwise to align mounting fastener hole. NOTE Install lower caliper mounting fastener (4). As the pistons are pushed back into the caliper, fluid level may rise more than 1/8 in.
Page 58 HOME sm00495 sm00496 Figure 1-41. Rear Brake Pad Spring Installed 1. Rear caliper mounting fasteners 2. Brake pad retainer 3. Rear caliper pin plug 4. Rear caliper pin hanger Figure 1-40. Rear Brake Caliper 1-36 2010 XB Service: Maintenance...
Page 59: Spark Plugs
HOME SPARK PLUGS 1.15 INSPECTION sm00099 Check spark plugs: Replace every 10,000 mile (16,000 km) service interval. Use only Harley-Davidson 10R12X spark plugs. Remove left side air scoop to access front cylinder spark plug. See 2.49 AIR SCOOPS. Disconnect cable from front spark plug. Using a 5/8 in.
Page 60 HOME 12. Apply LOCTITE ANTI-SEIZE to threads of spark plugs. 16. Install seat. Install and tighten spark plugs to 12-18 ft-lbs (16.3-24.7 Nm). sm00100 NOTE An extension may be needed to push on rear spark plug boot to verify it is seated properly. 13.
Page 61: Battery Maintenance
HOME BATTERY MAINTENANCE 1.16 GENERAL NOTE For charging information, see 1.16 BATTERY MAINTENANCE, Charging Battery. For testing information, see the electrical diagnostic manual. Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, sm04816 rubberized gloves and protective clothing when working with batteries.
Page 62: Battery Disconnection And Removal
HOME Table 1-10. Antidotes for Battery Acid CONTACT TREATMENT Never remove warning label attached to top of battery. Failure to read and understand all precautions contained External Flush with water. in warning, could result in death or serious injury. (00064a) Internal Drink large quantities of milk or water, followed Voltmeter Test...
Page 63 HOME Perform a voltmeter test to determine the state of charge. See the electrical diagnostic manual. If battery needs to be charged, proceed to the next step. Explosive hydrogen gas, which escapes during charging, could cause death or serious injury. Charge battery in a NOTE well-ventilated area.
Page 64 HOME Charge the battery once per month if stored in the vehicle. Charge the battery every three months if stored out of the vehicle. Connect the cables to the correct battery terminals. Failure to do so could result in damage to the motorcycle electrical NOTE system.
Page 65 HOME sm06717 sm06716 Figure 1-48. Battery Tender Connector: Firebolt Figure 1-47. Battery Tender Connector: Lightning sm06730 Figure 1-49. Battery Tender Connector: Ulysses 2010 XB Service: Maintenance 1-43...
Page 66: Steering Head Bearings
Loosen steering stem capnut and back off several turns. Do not operate motorcycle with loose, worn or damaged steering or suspension systems. Contact a Buell dealer Remove lower triple clamp pinch fasteners, two per side. for repairs. Loose, worn or damaged steering or suspen- Tighten steering stem capnut to 38-42 ft-lbs (51.5-56.9...
Page 67: Front Fork Oil Replacement
2.16 FRONT FORKS, Disassembly. The purpose of this subject is to provide a clear process for Refill and assemble fork assembly. See Final Assembly changing the fork oil on Buell motorcycles without completely under 2.16 FRONT FORKS, Assembly. disassembling the front fork assembly.
Page 68: Headlamp
HOME HEADLAMP 1.19 HEADLAMP ALIGNMENT om00029 The automatic-on headlamp feature provides increased visibility of the rider to other motorists. Be sure headlamp is on at all times. Poor visibility of rider to other motorists can result in death or serious injury. (00030b) NOTE Vehicles with multiple beam headlamps that are individually aimed should be adjusted so both lamps converge into one...
Page 69 HOME pd00326 pd00196 1. High beam adjuster (left) 2. Low beam adjuster (right) Figure 1-54. Horizontal Headlamp Adjustment Fastener: Figure 1-52. Headlamp Height Adjustment: Firebolt Lightning HEADLAMP ADJUSTMENT: LIGHTNING Horizontal Alignment pd00199 Figure 1-53 Figure 1-54. Loosen fasteners on right and left side of headlamp housing to adjust the horizontal alignment.
Page 70 HOME Vertical Alignment pd00202 Figure 1-57 Figure 1-58. Loosen fastener on the bottom of headlamp housing to adjust the vertical alignment. The ver- tical headlamp adjustment screw is located under the front upper fender. NOTE Only loosen headlamp alignment fastener enough to adjust headlamp.
Page 71: Windshield Maintenance
Failure to maintain polycarbonate properly can result in damage to the wind- screen/windshield. (00483d) Buell recommends using Harley Softcloths with the following products to clean your windscreen. To minimize swirl marks, cleaning should be done when motorcycle is cool and parked in the shade.
Page 72: Storage
HOME STORAGE 1.21 Wash and polish molded-in-color, painted and chrome- GENERAL plated surfaces. If motorcycle is to be covered, use a material that will breathe, such as light canvas. Plastic materials that do Do not store motorcycle with gasoline in tank within the not breathe promote the formation of condensation.
Page 73: Troubleshooting
HOME TROUBLESHOOTING 1.22 12. Fuel pump inoperative. GENERAL 13. Plugged fuel injectors. NOTE The troubleshooting section of this manual is a guide to dia- 14. Fuse blown. gnose problems. Read the appropriate sections of this manual Starts Hard before performing any work. Spark plugs in bad condition or have improper gap or are The following check list of possible operating troubles and their partially fouled.
Page 74 HOME Incorrect spark plug for the kind of service. Check Engine Light Illuminates During Operation Piston rings badly worn or broken. Fault detected. See the Electrical Diagnostic Manual for Valve guides or seals badly worn or damaged. this motorcycle. Pre-Ignition or Detonation (Knocks or Pings) LUBRICATION SYSTEM Fuel octane rating too low.
Page 75 HOME Oil diluted with gas. Clutch Slips Open in oiling circuit. Clutch controls improperly adjusted. High Oil Pressure Insufficient clutch spring tension. Oil tank overfilled. Worn friction discs. Bypass valve stuck in closed position. Clutch Drags Or Does Not Release Restricted oil tank return hose.
Page 76 HOME Rims and tires out-of-round or eccentric with hub: tire 10. Heavy front end loading. Non-standard equipment on the runout should not be more than 0.060 in. (1.5 mm). front end (such as heavy radio receivers, extra lighting equipment or luggage) tends to cause unstable handling. Irregular or peaked front tire tread wear.
Page 77 HOME Table 1-15. Front Suspension Problems TROUBLESHOOTING CONDITION ADJUSTMENT SOLUTION Not absorbing bumps. A good suspension is a balance between damping and track condition. Finding this balance requires exploring all possible compression settings. Lack of tire feedback. Increase compression damping. Tire slides.
Page 78 NOTES 1-56 2010 XB Service: Maintenance...
Page 79 TABLE OF CONTENTS SUBJECT..........................PAGE NO. 2.1 FASTENER TORQUE VALUES....................2-1 2.2 SPECIFICATIONS........................2-11 2.3 VEHICLE IDENTIFICATION NUMBER (VIN)................2-19 2.4 WHEELS..........................2-21 2.5 FRONT WHEEL........................2-23 2.6 REAR WHEEL.........................2-31 2.7 TIRES............................2-42 2.8 CHECKING CAST RIM RUNOUT...................2-48 2.9 FRONT BRAKE: EIGHT PISTON CALIPER................2-49 2.10 FRONT BRAKE: SIX PISTON CALIPER................2-58 2.11 BRAKE PEDAL........................2-66 2.12 REAR BRAKE MASTER CYLINDER..................2-67 2.13 REAR BRAKE LINE......................2-73...
Page 80 NOTES...
Page 81: Fastener Torque Values
HOME FASTENER TORQUE VALUES FASTENER TORQUE VALUES IN THIS CHAPTER The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE NOTES Axle (front) 39-41 ft-lbs 52.9-55.6 Nm 2.5 FRONT WHEEL, Installation/ANTI-SEIZE, left handed thread Axle (rear, final torque) 48-52 ft-lbs 65.1-70.5 Nm...
Page 82 HOME FASTENER TORQUE VALUE NOTES Belt guard fasteners 12-36 in-lbs 1.4-4.0 Nm 2.37 BELT GUARDS, Installation Brake caliper bleeder valve 36-60 in-lbs 4-6.8 Nm 2.9 FRONT BRAKE: EIGHT PISTON CAL- IPER, Front Brake Fluid Line Brake hand lever fastener, Firebolt 80-90 in-lbs 9-10.2 Nm 2.31 HANDLEBARS: FIREBOLT, Installation...
Page 83 HOME FASTENER TORQUE VALUE NOTES Brake reservoir cover fasteners, front 9-13 in-lbs 1-1.5 Nm 2.9 FRONT BRAKE: EIGHT PISTON CAL- IPER, Master Cylinder/Reservoir: Installation Brake reservoir fastener, rear 48-72 in-lbs 5.4-8 Nm 2.12 REAR BRAKE MASTER CYLINDER, Installa- tion: Firebolt/Lightning Brake reservoir fastener, rear 48-72 in-lbs 5.4-8 Nm...
Page 84 HOME FASTENER TORQUE VALUE NOTES Clutch hand lever fastener, Firebolt 60-84 in-lbs 6.8-9.5 Nm 2.31 HANDLEBARS: FIREBOLT, Installation Clutch hand lever fasteners 60-84 in-lbs 6.8-9.5 Nm 2.32 HANDLEBARS: LIGHTNING AND ULYSSES MODELS, Installation Clutch inspection cover fasteners 84-108 in-lbs 9.5-12 Nm 2.25 CLUTCH CONTROL, Assembly and Installa- tion/Tighten in a crosswise pattern Damper rod jamnut...
Page 85 HOME FASTENER TORQUE VALUE NOTES Front fender fasteners 36-48 in-lbs 4.0-5.4 Nm 2.15 FENDERS, Front Fender: XB12X/LOCTITE 271 (red) Front fender fasteners 36-48 in-lbs 4.0-5.4 Nm 2.15 FENDERS, Front Fender: XB12X/LOCTITE 271 (red) Front fender fasteners and washers 12-36 in-lbs 1.4-4 Nm 2.15 FENDERS, Front Fender: XB12XP Front fender fasteners and washers...
Page 86 HOME FASTENER TORQUE VALUE NOTES Ignition coil fasteners 120-144 in-lbs 13.6-16.3 Nm 2.24 THROTTLE CONTROL, Throttle Cable Replacement Inner ram air scoop fastener 12-36 in-lbs 1.4-4 Nm 2.49 AIR SCOOPS, Ram Air Scoop and Fan Shroud: Ulysses Instrument module fastener 12-36 in-lbs 1.4-4 Nm 2.27 FAIRING SUPPORT BRACKET: FIRE-...
Page 87 HOME FASTENER TORQUE VALUE NOTES Passenger seat latch, Firebolt 60-96 in-lbs 6.8-10.8 Nm 2.39 SUBFRAME TAIL ASSEMBLY AND BODY WORK: FIREBOLT, Assembly P clamp, front tie bar and clutch cable 25-27 ft-lbs 33.9-36.6 Nm 2.25 CLUTCH CONTROL, Assembly and Installa- tion Preload adjuster knob fastener 25-43 in-lbs...
Page 88 HOME FASTENER TORQUE VALUE NOTES Rider seat screws 12-36 in-lbs 1.4-4 Nm 2.51 SEAT, Firebolt Right front trunk pan fastener, Lightning 12-36 in-lbs 1.4-4 Nm 2.40 LEFT TAIL SECTION AND BATTERY PAN: LIGHTNING MODELS, Assembly Right front trunk pan fastener, Lightning 12-36 in-lbs 1.4-4 Nm 2.42 RIGHT TAIL SECTION: LIGHTNING...
Page 89 HOME FASTENER TORQUE VALUE NOTES Stone guard fasteners 12-36 in-lbs 1.4-4.0 Nm 2.37 BELT GUARDS, Installation Swingarm brace mounting fasteners 25-27 ft-lbs 33.9-36.6 Nm 2.19 SWINGARM AND BRACE, Brace Swingarm pivot shaft 44-46 ft-lbs 59.7-62.4 Nm 2.19 SWINGARM AND BRACE, Installation: Swingarm/ANTI-SEIZE Swingarm pivot shaft pinch fastener 17-19 ft-lbs...
Page 90 HOME FASTENER TORQUE VALUE NOTES Windshield mounting screw 25-30 in-lbs 2.8-3.4 Nm 2.48 WINDSHIELD AND WINDSCREEN: LIGHT- NING AND ULYSSES MODELS, Ulysses XB12XT/XB12XP Wire cover screws, Ulysses 36-48 in-lbs 4-5.4 Nm 2.44 CENTER TAIL LOOP: ULYSSES MODELS, Assembly Wire cover screws, Ulysses 36-48 in-lbs 4-5.4 Nm 2.52 SEAT LOCKS, Installation: Ulysses Models...
Page 91 HOME SPECIFICATIONS (GAWR) are given on an information decal located on the FIREBOLT steering head. NOTE Gross Vehicle Weight (GVWR) (maximum allowable loaded vehicle weight) and corresponding Gross Axle Weight Ratings Table 2-1. Weights: 2010 Firebolt and Lightning Models ITEM XB9SX XB12SX XB12R...
Page 92 HOME LIGHTNING Table 2-4. Dimensions: 2010 Firebolt and Lightning Models ITEM XB9SX, XB12SX XB12R XB12Scg XB12Ss Overall length 78.2 1985 76.2 1935 76.8 1950 81.9 2080 Overall width (without 32.7 28.1 29.7 29.7 mirrors) Overall height (without 42.5 1080 43.3 1100 41.3 1050...
Page 93 HOME ULYSSES Table 2-7. Capacities: 2010 XB12Ss ITEM U.S. LITERS Fuel tank total 4.40 gallons 16.7 (including reserve) Reserve/low fuel lamp 0.83 gallons illuminates at Engine oil (with filter) 2.5 quarts Transmission 1.0 quart Table 2-8. Dimensions: 2010 Ulysses Models ITEM XB12X XB12XT*...
Page 94 HOME Table 2-10. Capacities: 2010 Ulysses Models ITEM U.S. LITERS Do not inflate tire beyond maximum pressure as specified on sidewall. Over inflated tires can blow out, which could Fuel tank total 4.40 gallons 16.7 result in death or serious injury. (00027a) (including reserve) Reserve/low fuel lamp 0.83 gallons...
Page 95 Be sure tires are properly inflated, balanced and have Exceeding these weight ratings can affect stability and adequate tread. Inspect your tires regularly and see a Buell handling, which could result in death or serious injury. dealer for replacements. Riding with excessively worn,...
Page 96 HOME Table 2-12. Recommended Suspension Settings: 2010 Lightning XB9SX, XB12SX LOAD*** FRONT FORK REAR SHOCK *PRELOAD: **COMPRES- **REBOUND: PRELOAD **COMPRES- **REBOUND: TURNS IN SION: TURNS TURNS OUT POSITION SION: TURNS TURNS OUT FROM MIN- OUT FROM FROM MAX- OUT FROM FROM MAX- IMUM MAXIMUM...
Page 97 HOME Table 2-14. Recommended Suspension Settings: 2010 XB12Ss LOAD*** FRONT FORK REAR SHOCK *PRELOAD: **COMPRES- **REBOUND: PRELOAD **COMPRES- **REBOUND: TURNS IN SION: TURNS TURNS OUT POSITION SION: TURNS TURNS OUT FROM MIN- OUT FROM FROM MAX- OUT FROM FROM MAX- IMUM MAXIMUM IMUM...
Page 98 HOME Table 2-16. Recommended Suspension Settings: 2010 Ulysses XB12XT LOAD*** FRONT FORKS REAR SHOCK *PRELOAD: **COMPRES- **REBOUND: *PRELOAD: **COMPRES- **REBOUND: TURNS IN SION: TURNS TURNS OUT TURNS IN SION: TURNS TURNS OUT FROM MIN- OUT FROM FROM MAX- FROM MIN- OUT FROM FROM MAX- IMUM...
Page 99: Vehicle Identification Number (Vin)
Market designation (WMI code) 4MZ = Buell vehicles originally manufactured for sale within the United States 5MZ = Buell vehicles originally manufactured for sale outside the United States 95Z = Buell vehicles originally manufactured for sale in Brazil at Manaus CKD plant ®...
Page 100 HOME Table 2-17. Buell VIN Breakdown: 2010 Models POSITION DESCRIPTION POSSIBLE VALUES Model 0=Blast 2=XB9SX 3=XB12R 5=XB12Scg 6=XB12Ss 7=XB12X 9=XB12XP A=XB12XT B=1125R C=1125CR D=1125R, 105 HP France E=1125CR, 105 HP France F=XB12SX Sequential number Varies (last five digits) 2-20 2010 XB Service: Chassis...
Page 101: Wheels
HOME WHEELS GENERAL sm00110 Good handling and maximum tire mileage are directly related to the care of wheels and tires. Regularly inspect wheels and tires for damage and wear. If handling problems occur, see 1.22 TROUBLESHOOTING or refer to Table 2-18.
Page 102 Tires and wheels are critical items. Since the servicing of Buell tires are equipped with wear bars that run horizont- these components requires special tools and skills, Buell ally across the tread. When wear bars become visible and recommends that you see your dealer for these services.
Page 103: Front Wheel
HOME FRONT WHEEL REMOVAL sm00511 Place a scissor jack under jacking point and raise front wheel off ground. For location of jacking point see 4.19 EXHAUST SYSTEM. NOTE Do not operate front brake lever with front wheel removed or caliper pistons may be forced out. Reseating pistons requires caliper disassembly.
Page 104 HOME 50A) WHEEL BEARING REMOVER sm00513 INSTALLER (Part No. HD-44060C). Sparingly apply EXTREME PRESSURE LUB- RICANT (Part No. J-23444-A) to the threads of the short forcing screw (1) to prolong service life and provide smooth operation. Assemble the short forcing screw (1), nut (2), bearing (3), washer (4) and bridge (5).
Page 105 HOME sm00515 sm00517 1. Bridge 2. Nut 3. Forcing screw Figure 2-10. Remove the Spacer Figure 2-8. Remove the Bearing Front Rotor Removal Figure 2-16. Remove and discard rotor mounting fasteners (7). sm00516 Remove and inspect brake rotor (6) for wear and warping. 2.10 FRONT BRAKE: SIX PISTON CALIPER, Brake Caliper: Cleaning and Inspection.
Page 106 HOME ASSEMBLY sm00518 PART NUMBER TOOL NAME B-43993-10 FRONT WHEEL BEARING INSTALLER B-43993-11 FRONT BACKING PLATE WHEEL B-43993-50A WHEEL BEARING REMOVER/INSTALLER KIT B-43993-7 FRONT WHEEL BEARING REMOVER COLLET B-43993-9 FRONT BEARING INSTALLER B-43993-9, FROM FRONT BEARING INSTALLER KIT PART NO. B- 43993-50A HD-44060A WHEEL BEARING...
Page 107 HOME sm00519 sm00520 1. Forcing screw 2. Backing plate Figure 2-13. Insert Forcing Screw and Backing Plate Figure 2-13. Remove the backing plate (2) from the long forcing screw (1). Install the backing plate onto the 1. Long forcing screw forcing screw, with the smaller diameter toward the hex- 2.
Page 108 HOME NOTE sm00522 Figure 2-14. Center the spacer (2) while installing the wheel bearing. Failure to center the spacer could cause the bearing not to pull in straight. 11. See Figure 2-15. Insert a new wheel bearing (1) squarely into the hub, with the lettered side facing out (away from the wheel).
Page 109 HOME sm00523 Front axle Front brake springs (6) Rotor mount fastener (6) Wheel bearing Front wheel spacer Drive bushings (6) Front wheel Front brake rotor Washer (6) Figure 2-16. Front Wheel Assembly Front Rotor Installation Figure 2-16. Install new springs (4). Rotor mounting fasteners must be seated into drive Install new washers (9).
Page 110 HOME Figure 2-17. Install caliper. sm00511 Align wheel so that rotor mounting fasteners straddle caliper. Rotate right front fork counterclockwise to align caliper with rotor. Lower front wheel into caliper assembly. NOTE The front axle is left hand thread. Install front axle. Apply LOCTITE ANTI-SEIZE LUBRICANT to axle.
Page 111: Rear Wheel
HOME REAR WHEEL REMOVAL CLEANING AND INSPECTION Place a scissor jack under jacking point and raise rear wheel off ground. For location of jacking point see 4.19 EXHAUST SYSTEM. Using compressed air to "spin dry" bearings can cause NOTE bearing to fly apart, which could result in death or serious injury.
Page 112 HOME Brake Rotor DISASSEMBLY Figure 2-21. Remove sprocket. Remove sprocket fasteners (7) and washers. Discard fasteners. Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake Remove sprocket (6) from wheel. components. (00319c) Remove rear rotor.
Page 113 HOME sm00525a Rotor mounting fastener (6) Wheel spacer Brake rotor Wheel Wheel spacer (right side) Sprocket Wheel seal (2) Sprocket fastener Wheel bearing (3) Axle Figure 2-21. Rear Wheel Assembly 2010 XB Service: Chassis 2-33...
Page 114 HOME 10. Remove the ball bearing (5) and wheel bearing (6) from WHEEL BEARINGS: TWO BEARING the collet (4). WHEELS 11. See Figure 2-27. Remove the spacer. PART NUMBER TOOL NAME B-43993-10 BEARING INSTALLER, FRONT sm00512 BEARING B-43993-11 BACKING PLATE B-43993-50A WHEEL BEARING REMOVER/INSTALLER KIT...
Page 115 HOME sm00514 sm00516 1. Nut 2. Bridge 3. Forcing screw 1. Puller assembly 4. Collet 2. Collet 5. Ball bearing 3. Forcing screw 6. Wheel bearing Figure 2-24. Expand the Collet Figure 2-26. Removing Bearing from Puller sm00515 sm00517 1. Bridge 2.
Page 116 HOME WHEEL BEARING INSTALLER AND REMOVER (Part sm00519 No. HD-44060-C), with the smaller diameter toward the wheel hub. Insert the forcing screw and backing plate into the wheel hub. Figure 2-29. Sparingly apply EXTREME PRESSURE LUBRICANT (Part No. J-23444-A) to the threads of the long forcing screw (1).
Page 117 5. Bearing sm00521 6. Nut Figure 2-32. Install the Bearing WHEEL BEARINGS: THREE BEARING WHEELS PART NUMBER TOOL NAME 217801 NICE BEARING B-50019 BUELL WHEEL BEARING INSTALLER/REMOVER B50019-2 SPACER B-50019-3 BEARING INSTALLER B-50019-4 BEARING INSTALLER B-50019-5 BEARING REMOVER 1. Forcing screw...
Page 118 HOME sm00525a Rotor mounting fastener (6) Wheel spacer Brake rotor Wheel Wheel spacer (right side) Sprocket Wheel seal (2) Sprocket fastener Wheel bearing (3) Axle Figure 2-33. Rear Wheel Assembly Figure 2-33Remove the axle spacer from the brake Lightly apply EXTREME PRESSURE LUBRICANT (Part rotor side and remove the bearing seal from the rotor side No.
Page 119 2. Nut 3. Washer Assemble the BOLT (Part No. B-50019-8) (1) from the 4. Bearing Buell bearing installer kit and the smaller BEARING 5. Bridge INSTALLER (Part No. B-50019-3) (2). 6. Spacer Fit rotor side bearing with the engraved letters facing out.
Page 120 HOME Installation: Sprocket Side sm06748 Assemble the bolt and the rotor side bearing installer. Lightly apply pressure lubricant to the threads of the forcing screw. NOTE Do not press in the inner wheel bearing without installing the wheel spacer. Slide the bolt through the rotor side bearing and slide the wheel spacer on over the bolt and inside the wheel.
Page 121 HOME Figure 2-41. Tighten rear axle (1) to 23-27 ft-lbs (31.2- INSTALLATION 36.6 Nm), loosen two full turns and then retighten to 48- Center rear wheel in the swingarm at the same time sliding 52 ft-lbs (65.1-70.5 Nm). the drive belt onto the rear sprocket. Tighten pinch fastener (2) on right side of swingarm to 40- With wheel centered in swingarm, lower motorcycle to 45 ft-lbs (54.2-61 Nm).
Page 122: Tires
New tires should be stored in a horizontal tire rack. Avoid stacking new tires in a vertical stack. The weight of the stack Use only Buell approved tires. See a Buell dealer. Using compresses the tires and closes down the beads.
Page 123 HOME Table 2-21. Tires: 2010 XB Models MODEL FRONT/REAR APPROVED BRAND SIZE ALL LOADS TO GVWR XB12Ss Front Pirelli Scorpion SYNC 120/70 ZR 17 XB12Scg Rear Pirelli Scorpion SYNC 180/55 ZR 17 XB12XT Front Pirelli Diablo Angel ST 120/70 ZR 17 Rear Pirelli Diablo Angel STE 180/55 ZR 17...
Page 124 Figure 2-46. Valve Stem Using the Tire Machine Use only Buell approved tires. See a Buell dealer. Using non-approved tires can adversely affect stability, which could result in death or serious injury. (00133a) Tires are a critical safety component. Contact a Buell dealer for tire repair or replacement.
Page 125 HOME sm05618 sm05355 Figure 2-48. Tire Bead at Bottom of Rim Well Figure 2-49. Tire and Wheel Balance Dots 2010 XB Service: Chassis 2-45...
Page 126 HOME sm05629 sm04915 1. Gauge 2. Lateral runout Figure 2-50. Feeding the Upper Bead onto the Rim Figure 2-51. Lateral Runout Inflate Tire Radial Figure 2-52. Turn wheel on axle and measure tire radial runout. Refer to Table 2-22. Do not exceed manufacturer's recommended pressure to seat beads.
Page 127 HOME Allow eight hours for adhesive to cure completely before ADJUSTMENT using wheel. PART NUMBER TOOL NAME NOTE HD-99500-80 WHEEL TRUING AND BALANCING If wheel assembly is out of specification (1 oz. front, 2 oz. rear) STAND rotate tire on rim and rebalance until wheel is within specifica- Wheel Balancing tion.
Page 128: Checking Cast Rim Runout
HOME CHECKING CAST RIM RUNOUT GENERAL sm00111 PART NUMBER TOOL NAME HD-99500-80 WHEEL TRUING AND BALANCING STAND Before installing a new tire, check wheels for lateral and radial runout. Rim Lateral Runout Figure 2-54. Install truing arbor in wheel hub and place wheel in the WHEEL TRUING AND BALANCING STAND (Part No.
Page 129: Front Brake: Eight Piston Caliper
HOME FRONT BRAKE: EIGHT PISTON CALIPER FRONT BRAKE HAND LEVER Figure 2-56. Remove pivot bolt nut (1) and pivot bolt D.O.T. 4 brake fluid will damage painted and body panel (2) to detach the brake hand lever (3). surfaces it comes in contact with. Always use caution and To install, lubricate pivot bolt with LOCTITE ANTI-SEIZE.
Page 130 HOME Figure 2-60. Press piston assembly (1) and remove sm04577 internal circlip (2) and discard. Remove piston and spring from master cylinder and dis- card. sm00529 Figure 2-58. Master Cylinder/Reservoir Banjo Bolt 1. Piston assembly 2. Circlip sm04578 Figure 2-60. Piston Assembly in Master Cylinder Cleaning and Inspection Use denatured alcohol to clean brake system components.
Page 131 HOME Inspect the outlet port that mates with the fluid line banjo sm05440 fitting. Replace the housing if any scratches, dents or other damage is present. Clean the reservoir diaphragm, stiffener and cover. Clean the pressure relief channels (2) in the cover. sm05442 Figure 2-61.
Page 132 HOME Connect the brake fluid line (6) to the master cylinder/reser- sm05439 voir using two new copper washers (7) and banjo bolt (8) and tighten to 16-20 ft-lbs (22-27 Nm). NOTE Use only new copper crush banjo washers with D.O.T. 4 brake fluid.
Page 133 HOME Remove caliper banjo bolt (2) and two copper washers to sm04586 disconnect brake line from caliper. Discard copper washers. Remove master cylinder banjo bolt and two copper washers to disconnect brake line from master cyl- inder/reservoir. Discard copper washers. NOTE On 12Ss, XB12Scg &...
Page 134 HOME sm05391 Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and master cylinder bore are clean and undamaged before assembly. (00322a) Connect the brake fluid line to caliper using two new copper washers and a banjo bolt. Finger tighten the banjo bolt into the front caliper. Tighten the master cylinder/reservoir banjo bolt to 16-20 ft-lbs (21.7-27.1 Nm).
Page 135 HOME sb00028 sm05522 Figure 2-68. Front Brake Line Guide: 12Ss, XB12Scg & XB12SX Models Only 1. Brake line 2. Front brake caliper CALIPER: REMOVAL AND INSTALLATION 3. Caliper mounting fastener (2) Removal Figure 2-69. Front Brake Caliper Mounts Drain brake fluid into a suitable container. Discard used fluid according to local laws.
Page 136 HOME sm05524 Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) Test the brake light. CALIPER: REPAIR PART NUMBER TOOL NAME B-42887 BRAKE CALIPER PISTON REMOVER Disassembly Figure 2-70.
Page 137 HOME Measure and inspect brake pads and rotor. Replace as Install two new O-rings in grooves of each piston bore. required. See 1.14 BRAKE SYSTEM MAINTENANCE. Install pistons in each piston bore. Assembly Install new O-rings (10) between caliper halves. Figure 2-72.
Page 138: Front Brake: Six Piston Caliper
HOME FRONT BRAKE: SIX PISTON CALIPER 2.10 MASTER CYLINDER RESERVOIR REMOVAL sm00528 On XB9SX, XB12X, XB12XT and XB12XP models, remove the right deflector. See 2.28 DEFLECTORS. Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention.
Page 139 HOME MASTER CYLINDER AND HAND LEVER MASTER CYLINDER: CLEANING AND DISASSEMBLY INSPECTION Brake Hand Lever Figure 2-73. On XB9SX, XB12XT, XB12XP and Use denatured alcohol to clean brake system components. XB12X models, remove the pivot shaft riser and nut (9) Do not use mineral-based solvents (such as gasoline or from the brake pivot shaft (18) to detach the brake hand paint thinner), which will deteriorate rubber parts even...
Page 140 HOME Figure 2-77. Remove two master cylinder cover sm00530 screws, cover and cover gasket. D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is per- formed.
Page 141 HOME On Ulysses models, remove fasteners (4) on right lower sm00531 fender. NOTE Damaged banjo bolt seating surfaces will leak when reas- sembled. Prevent damage to seating surfaces by carefully removing brake line components. Figure 2-73. Remove master cylinder banjo bolt (metric) (14) and two copper washers (16) to disconnect brake line from master cylinder.
Page 142 HOME On Firebolt and Lightning models, use the following steps sm00533 to install the brake line to caliper. Figure 2-78. Install new copper washer (3), brake line, new copper washer (3) and wire form (4) onto banjo bolt (2). Finger tighten banjo bolt (2) onto front caliper, being careful not to pinch wire form (4) while tightening.
Page 143 HOME sm00535 Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) Only Ulysses models, remove fasteners on lower right fender. See 2.15 FENDERS. Figure 2-80. Disconnect brake line (1) at caliper (2). 2.10 FRONT BRAKE: SIX PISTON CALIPER, Brake Line Removal.
Page 144 HOME INSTALLATION Figure 2-83. Install pad spring (7) and brake pads Always replace brake pads in complete sets for correct (10). and safe brake operation. Improper brake operation could Install pin hanger set (1) and tighten to 132-168 in-lbs result in death or serious injury. (00111a) (14.9-19 Nm).
Page 145 HOME sm00537 Pin hanger set Piston Caliper mounting fasteners Brake bleeder Piston O-rings Bleeder cap Pad spring Brake pads Caliper Small O-ring Caliper fasteners (4) Figure 2-83. Front Caliper Assembly 2010 XB Service: Chassis 2-65...
Page 146: Brake Pedal
HOME BRAKE PEDAL 2.11 REMOVAL sm00119 Figure 2-84. Remove cotter pin (3) and discard. Remove clevis pin (2). Remove pedal fastener (4). Remove shift brake pedal sleeve (5). Remove pedal bushings (6). Remove brake pedal (7). INSTALLATION Figure 2-84. Install pedal bushings (6). Install shift brake pedal sleeve (5).
Page 147: Rear Brake Master Cylinder
HOME REAR BRAKE MASTER CYLINDER 2.12 REMOVAL: FIREBOLT/LIGHTNING sm00539 Figure 2-85. Drain brake fluid into a suitable container. Discard used fluid according to local laws. Install a length of plastic tubing over caliper bleeder valve. Place free end in a suitable container. Open bleeder valve (metric) about 1/2-turn.
Page 148 HOME 10. See Figure 2-89 Figure 2-90. Detach remote reservoir. sm00541 Remove top clamp (4) on hose connected to master cylinder. Disconnect hose. Remove fastener (2) to detach reservoir (1) from frame if necessary. sm00538 1. Reservoir 2. Fastener and washer 3.
Page 149 HOME Remove cotter pin from brake pedal. See 2.11 BRAKE Remove fasteners (11) to detach master cylinder (4) from PEDAL. rider footpeg mount. Remove seat. Figure 2-94. Detach remote reservoir. Remove top clamp (2) on hose connected to master Figure 2-93.
Page 150 HOME Remove piston assembly (4) from master cylinder body sm00548 (1). Loosen adjuster locknut on the rod assembly (3). Remove the clevis from the rod assembly (3). NOTE Do not disassemble master cylinder unless problems are experienced. Discard all seals during the disassembly pro- cedure.
Page 151 HOME Add brake fluid and bleed brake system. See 1.14 BRAKE sm00542 SYSTEM MAINTENANCE. Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure.
Page 152 HOME Be sure that all lights and switches operate properly before After installing seat, pull upward on seat to be sure it is operating motorcycle. Low visibility of rider can result in locked in position. While riding, a loose seat can shift death or serious injury.
Page 153: Rear Brake Line
HOME REAR BRAKE LINE 2.13 REMOVAL: FIREBOLT sm00538 Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect battery by unthreading fastener removing negative cable (black) from battery first. See 1.16 BAT- TERY MAINTENANCE.
Page 154: Installation: Firebolt
HOME Install seat. sm00551 Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) 10. Turn ignition key ON, press rear brake pedal and check for proper brake light operation. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure.
Page 155 HOME Remove banjo bolt (3) from rear caliper. Discard copper Install seat. washers. Figure 2-99. Remove brake line switch/banjo bolt from rear master cylinder. Discard copper washer. Be sure that all lights and switches operate properly before 10. Remove brake line from motorcycle. operating motorcycle.
Page 156 HOME Figure 2-103. Remove brake line switch/banjo bolt sm00553 from rear master cylinder. Discard copper washers. Remove brake line bracket fasteners. 10. Remove brake line from motorcycle. sm00863b Figure 2-103. Rear Brake Light Switch/Banjo Bolt: Ulysses INSTALLATION: ULYSSES Figure 2-101. Rear Brake Light Switch Connector (Ulysses) Route the brake line.
Page 157 HOME 10. Turn ignition key ON, press rear brake pedal and check for proper brake light operation. After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or After servicing brakes and before moving motorcycle, serious injury.
Page 158: Rear Brake Caliper
HOME REAR BRAKE CALIPER 2.14 REMOVAL DISASSEMBLY NOTE PART NUMBER TOOL NAME Steps 1 and 2 are not required for detaching caliper from rotor. B-42887 BRAKE CALIPER PISTON REMOVER Drain fluid only when disassembling caliper. Figure 2-104. Remove pin plug (5) and pad hanger (metric) to free brake pads.
Page 159 HOME sm00556 Table 2-26. Rear Rotor Runout RUNOUT Rotor radial 0.0177 0.45 Rotor lateral 0.0154 0.39 ASSEMBLY Figure 2-105. Place clip (1) inside caliper body as shown. NOTE To verify proper brake pad-to-brake rotor clearance when the caliper is installed, piston must be pressed all the way into the bore whenever new brake pads are used.
Page 160 HOME Figure 2-104. Install caliper assembly on caliper Turn ignition key switch to ON. Apply brake pedal to test mount. Brake pad surfaces must face rear brake rotor. brake lamp operation. Turn ignition key switch to LOCK. Install large caliper fastener (7) (metric) tightening to 18-21 ft-lbs (24.7-28.5 Nm).
Page 161: Fenders
HOME FENDERS 2.15 FRONT FENDER: XB12R/XB9SX/XB12SX/XB12SCG/XB12XT sm04238 Removal Figure 2-109. Remove fasteners and washers (2) securing the front fender (1) to front forks. Carefully remove front fender. Installation Figure 2-109. Align front fender (1) to fender mounts on front forks. Use LOCTITE 271 (red) on all fasteners and install front fender (1) with fasteners and washers (2) and tighten to 36-48 in-lbs (4-5.4 Nm).
Page 162 HOME front fender fasteners and washers (1) and tighten to 12-36 sm00654 in-lbs (1.4-4 Nm). Install fastener and washer (3) into headlight assembly and tighten to 36-48 in-lbs (4.0-5.4 Nm). REAR FENDER: XB12SS/XB12XT/XB12X Removal Figure 2-110. Remove fender fasteners (11). Remove rear fender (10).
Page 163: Front Forks
HOME FRONT FORKS 2.16 REMOVAL sm00559 Remove front fender. See 2.15 FENDERS Remove front wheel. See 2.5 FRONT WHEEL. Remove caliper mounting fasteners. See 2.10 FRONT BRAKE: SIX PISTON CALIPER, Brake Caliper Removal. Figure 2-112. Loosen upper and lower fork clamp pinch fasteners (1, 5).
Page 164 Harley-Davidson Touring models only and are not to be used on Buell Loosen the damper rod assembly jamnut (3) and back it models.
Page 165 HOME 10. See Figure 2-119. Inside the damper rod assembly (6) is sm03822 a fork push rod (4) that is tapered on one end to control the movement of fluid in the front fork increasing and decreasing the damping properties. The fork push rod is attached o the fork cap.
Page 166 HOME sm03826 Fork cap Bolt, center Guide bushing Seat, rubber Spring collar Seal spacer Slider piston Spring joint Oil seal Push rod Spring Oil seal stopper ring Damper jamnut Stopper ring Dust seal Damper rod assembly Outer tube Slider fork Centering plate Reflector assembly Axle clamp bolt...
Page 167 Table 2-27. Fork Spring Service Wear Limit NOTE MODEL Figure 2-121. For Buell model motorcycles, there are three XB9R, XB12R 14.31 363.6 different tools that can be used to install the fork seal and dust XB9SX, XB12SX, XB12Ss 14.31...
Page 168 HOME With the fork fully collapsed, fill the fork with oil until it sm00569 reaches the threads on the outer tube. Figure 2-122. Obtain damper rod retrieval tool found in the Race Tech Inc. FORK BLEED TOO SET. Thread damper rod retrieval tool found in the Race Tech Inc. DAMPER ROD RETRIEVAL TOOL (Part No.
Page 169 HOME 17. See Figure 2-119. Thread fork cap (3) into fork tube (18) Install fork assembly into upper fork clamp. and tighten to 22-30 ft-lbs (29.8-40.7 Nm). Table 2-28. Fork Oil Levels: XB12X/XB12XT Adjust both forks equally. Improper fork adjustment can MODEL lead to loss of control, which could result in death or ser- ious injury.
Page 170: Fork Clamps
HOME FORK CLAMPS 2.17 REMOVAL FIREBOLT: sm00573 Place a scissor jack under jacking point and raise front wheel off ground. For location of jacking point see 4.19 EXHAUST SYSTEM. Remove handlebars. See 2.31 HANDLEBARS: FIRE- BOLT. Remove cable straps securing wiring harnesses to the upper fork clamp.
Page 171: Removal: Lightning/Ulysses
HOME NOTE Remove the upper fork clamp (4). Carefully install the fork into the upper fork clamp. Forcing the Remove the lower fork clamp with stem (6). fork into the upper fork clamp could move the stopper ring out of the groove which will not allow the correct clamp load. steering head bearings...
Page 172 HOME Install steering stem capnut (1). Tighten but do not torque. NOTE For additional information, see 2.16 FRONT FORKS. Install one front fork assembly into lower fork clamp with stem (6). Figure 2-124. Position both forks with same number alignment lines (4) visible and reflectors facing to the sides. Figure 2-119.
Page 173: Steering Head Bearings
HOME STEERING HEAD BEARINGS 2.18 REMOVAL INSTALLATION Place a scissor jack under jacking point and raise front PART NUMBER TOOL NAME wheel off ground. For location of jacking point see B-43993-12 BACKING PLATE 4.19 EXHAUST SYSTEM. B-45521 STEERING HEAD BEARING Remove brake lever housing.
Page 174 HOME sm00576 sm00578 1. Forcing screw 2. Steering Head Bearing Installation Tool 3. Lower bearing 4. Bearing 5. Washer 6. Nut Figure 2-130. Lower Bearing Figure 2-130. Sparingly apply EXTREME PRESSURE LUBRICANT (Part No. J-23444-A) to the threads of the forcing screw (1) from the steering head bearing race 1.
Page 175 HOME 12. Install steering stem pinch bolt applying LOCTITE 271 sm00579 (red) and tightening to 20-22 ft-lbs (27.1-29.8 Nm). 13. Apply LOCTITE 271 (red) to upper triple clamp fasteners and tighten to 23-25 ft-lbs (31.2-33.9 Nm). 14. On Lightning and Ulysses models, install front modules. 2.30 FRONT MODULES: LIGHTNING AND ULYSSES MODELS.
Page 176: Swingarm And Brace
HOME SWINGARM AND BRACE 2.19 GENERAL sm00302 The swingarm also serves as the oil tank. For information on the swingarm function as the oil tank, see 3.11 OIL RESER- VOIR AND OIL HOSE ROUTING. The swingarm features a removable brace on the right side to allow drive belt replacement.
Page 177: Disassembly
HOME sm00581 Swingarm Oil drain plug Dipstick Pivot shaft Swingarm bushings Brace fastener (4) Swingarm spacer Swingarm brace Swingarm bearing (5) Rear axle pinch fastener Engine crankcase Jiffy Tite oil line fittings (3) 7. Pivot shaft pinch fastener with nut Figure 2-133.
Page 178: Assembly
HOME Check that swingarm is not bent or twisted. Replace if sm00585 damaged. ASSEMBLY PART NUMBER TOOL NAME HD-44060-6 BEARING INSTALLER Swingarm Figure 2-133. Install new shock mount bushings (3). Install new bearings (5) and spacer (4) with BEARING INSTALLER (Part No. HD-44060-6) by lightly seating spacer.
Page 179 HOME Install rear fender. See 2.15 FENDERS. 14. Connect battery cables to battery: positive cable (red) first. Tighten to 60-70 in-lbs (6.8-7.9 Nm). See 1.16 BATTERY Install rear inner fender and tighten fasteners to 12-36 in- MAINTENANCE. lbs (1.4-4 Nm). Connect three oil lines to swingarm fittings and install and tighten p-clamps to 48-72 in-lbs (5.4-8 Nm).
Page 180: Front And Rear Isolators
HOME FRONT AND REAR ISOLATORS 2.20 FRONT ISOLATOR sm05389 Removal NOTE Avoid cross-threading front isolator bolt or insert. Keep weight of motorcycle off front isolator by alternately loosening front isolator bolt and raising scissor jack to support engine. Place a scissor jack under jacking point for supporting engine only.
Page 181: Frame Pucks
HOME FRAME PUCKS 2.21 REMOVAL Surface Primer contains ethyl benzene and toluene, chemicals known to the State of California to cause cancer The aluminum frame of this motorcycle is the fuel tank. and birth defects or other reproductive harm. (00453b) Drilling, welding, cutting, grinding, sanding, polishing or Carefully follow the directions on the primer/appilicator other modifications to this frame can weaken it or cause...
Page 182 HOME is00878 is00880 Figure 2-138. Outline the Entire Puck 1. Directional point 2. Horizontal crease 3. V-shaped edge is00881 Figure 2-137. Puck Orientation Figure 2-139. Pressing Puck to Frame 2-102 2010 XB Service: Chassis...
Page 183: Frame
HOME FRAME 2.22 REMOVAL sm00914 Remove fuel from frame. See 4.14 FUEL PUMP, Draining Fuel Tank. Rotate engine. See 3.4 ENGINE ROTATION FOR SER- VICE. Remove exhaust header. See 4.19 EXHAUST SYSTEM. For Firebolt and Lightning models, remove subframe tail assembly.
Page 184: Rear Shock Absorber
HOME REAR SHOCK ABSORBER 2.23 GENERAL The rear suspension is controlled by the shock absorber. The shock allows adjustment of rear compression and rebound damping and spring preload. sm00588 Shock remote reservoir clamp fastener Lower shock mount Shock remote reservoir clamp Lower shock mount sleeve Shock remote reservoir Lower shock mount fastener...
Page 185 HOME sm00591 XB9SX XB12SX XB12Ss XB12Scg Remote reservoir clamp fastener Lower shock mount fastener Remote reservoir clamp Shock reservoir body Remote reservoir Upper shock mount fastener Lower shock mount nut Lower shock mount Washers (2) Shock spring retainer kit Lower shock mount sleeve Rear shock spring Figure 2-142.
Page 186: Removal: Firebolt
HOME sm00594 Screw and washer, preload adjuster knob Lower shock mount nut Preload adjuster knob Lower shock mount washer, thick Preload adjust assembly Lower shock mount washer, thin Preload adjuster fasteners (2) Lower shock mount sleeve Rear shock body Lower shock mount fastener Remote reservoir clamp fastener Upper shock mount fastener Remote reservoir clamp...
Page 187: Removal: Lightning
HOME Disconnect and remove battery. See 1.16 BATTERY Figure 2-142. Remove the nut (4) and washer (5) MAINTENANCE. from the lower shock bolt and raise scissor jack until the lower bolt can be removed by hand. Remove tail body work. See 2.39 SUBFRAME TAIL ASSEMBLY AND BODY WORK: FIREBOLT.
Page 188: Installation: Firebolt
HOME covering the shock absorber in order to remove certain components for the procedure. See 2.49 AIR SCOOPS. On XB12XT models it will be necessary to remove Connect positive (+) battery cable first. If positive (+) cable saddlebags and brackets. See 4.4 ELECTRONIC CON- should contact ground with negative (-) cable connected, TROL MODULE...
Page 189: Installation: Ulysses
HOME Install upper shock bolt and tighten to 48-52 ft-lbs (65.1- 70.5 Nm). Connect positive (+) battery cable first. If positive (+) cable Install the two fasteners holding the preload adjuster in should contact ground with negative (-) cable connected, place and tighten to 36-60in-lbs (4.1-6.8 Nm).
Page 190: Throttle Control
HOME THROTTLE CONTROL 2.24 REMOVAL AND DISASSEMBLY sm00597 Remove right handlebar deflector if required. See 2.28 DEFLECTORS. NOTE On Ulysses models, it will be necessary to disconnect and remove the heated handgrips. See 6.11 HEATED HAND GRIPS: ULYSSES MODELS. Figure 2-149.
Page 191: Throttle Cable Replacement
HOME Position the lower idle control cable barrel in the throttle THROTTLE CABLE REPLACEMENT cam wheel of the throttle body and then slip the elbow into Removal the slotted hole in the throttle cable mounting bracket. Position the throttle control cable in the same manner so NOTE both elbows are inserted into the bracket.
Page 192 HOME sm03924 sm03923 Figure 2-151. Throttle Cable Retention Clip Figure 2-152. Throttle Cable Retention Clip, Inside View sm04534 Figure 2-153. Throttle cable elbow alignment 2-112 2010 XB Service: Chassis...
Page 193: Clutch Control
HOME CLUTCH CONTROL 2.25 GENERAL sm04195 For clutch adjustment, see 1.9 CLUTCH/TRANSMIS- SION/PRIMARY FLUID. For clutch replacement, see CLUTCH. REMOVAL AND DISASSEMBLY Clutch Cable Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding.
Page 194 HOME 13. See Figure 2-158. Remove the outer ramp and hook (1) 14. See Figure 2-159. Unscrew the cable fitting from the from the cable end (3) and coupling (2). Remove cable primary cover. Remove clutch cable and fitting. end from slot in coupling. See 5.4 CLUTCH RELEASE 15.
Page 195: Assembly And Installation
HOME Figure 2-157. Install (7) bearings and (8) sleeve into sm00268 the shift lever. After applying LOCTITE 271 (red), install flange bolt (6) and shift pedal (4) to primary cover, and tighten to 22-24 ft-lbs (29.8-32.5 Nm). After applying LOCTITE 271 (red), tighten engine shift lever pinch screw to 48-60 in-lbs (5.4-6.8 Nm).
Page 196 HOME NOTE 19. Connect negative battery cable to battery terminal.Tighten Always connect front tie bar to engine mount first. fastener to 60-70 in-lbs (6.8-7.9 Nm). 15. Install front tie bar, p-clamp and clutch cable to front engine mount and tighten fastener to 25-27 ft-lbs (33.9-36.6 Nm). 16.
Page 197: Headlamp Assembly And Support Bracket
HOME HEADLAMP ASSEMBLY AND SUPPORT BRACKET 2.26 REMOVAL: FIREBOLT sm00605 Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect battery cables from battery: negative cable (black) first. See 1.16 BATTERY MAINTENANCE.
Page 198: Installation: Firebolt
HOME sm00606 Headlight pivot fasteners Headlight fastener Headlight support bracket High beam headlight Electronic control module fasteners Headlight bulb Black rubber cover Bank angle sensor Low beam headlight Bank angle sensor fastener with washers Figure 2-163. Headlight Support Bracket Assembly: Firebolt INSTALLATION: FIREBOLT 11.
Page 199: Removal: Lightning/Ulysses
HOME Remove windscreen and windshield. See 2.48 WIND- sm00607 SHIELD WINDSCREEN: LIGHTNING ULYSSES MODELS. Disconnect horn connectors [122] (2). For Lightning Models: See Figure 2-165. For Ulysses: See Figure 2-166. NOTE Horn (1) can remain attached to support bracket. The horn can be removed and replaced as needed.
Page 200 HOME sm00608 Horn Fasteners (2), upper headlight mounting Horn connectors [122] Headlight assembly Horn bracket Fasteners (2), headlight support bracket Horn fastener Headlight support bracket Headlight connector [38] Left and right front modules Figure 2-165. Electrical Connectors Behind Windscreen: Lightning 2-120 2010 XB Service: Chassis...
Page 201: Disassembly: Lightning/Ulysses
HOME sm00621 Horn Screws (2), upper headlight mounting Horn connectors [122] Headlight assembly Horn bracket Screws (2), headlight support bracket Horn fastener Headlight support bracket Headlight connector [38] Left and right front modules Figure 2-166. Headlight and Support Bracket: Ulysses DISASSEMBLY: LIGHTNING/ULYSSES ASSEMBLY: LIGHTNING/ULYSSES Figure...
Page 202: Installation: Lightning/Ulysses
HOME sm00622 Boot (2) Wiring harness Bulb holder (2) Position bulb socket (used for HDI only) Bulb (2) Headlight connector 4. Headlight housing Figure 2-167. Headlight Assembly Connect horn connectors [122] (2). INSTALLATION: LIGHTNING/ULYSSES Adjust headlights. See 1.19 HEADLAMP. Install headlight support bracket (9). For Lightning Models: See Figure 2-165.
Page 203: Fairing Support Bracket: Firebolt
HOME FAIRING SUPPORT BRACKET: FIREBOLT 2.27 Connect instrument cluster connector and install instru- REMOVAL ment cluster. Tightening to 12-36 in-lbs (1.4-4 Nm). See Remove seat. 6.25 INSTRUMENT MODULE. Install horn and tighten fasteners to 72-96 in-lbs (8-10.8 Nm). See 6.12 HORN.
Page 204 HOME sm00625 Jam nut Fairing support bracket Washer Instrument cluster Rubber grommet P-clamp Fairing support bracket fasteners and washers P-clamp fastener and washers Figure 2-168. Fairing Support Bracket Assembly: Firebolt 2-124 2010 XB Service: Chassis...
Page 205: Deflectors
HOME DEFLECTORS 2.28 REMOVAL AND DISASSEMBLY ASSEMBLY AND INSTALLATION Figure 2-169. Remove fasteners (2) from clutch and Install brake and clutch levers with pivot shafts (3, 6). See brake pivot shafts (3, 6) and pivot shaft risers (4). 2.25 CLUTCH CONTROL 2.10 FRONT BRAKE: SIX PISTON CALIPER.
Page 206: Grille: Xb9Sx/Xb12X/Xb12Xp/Xb12Sx
HOME GRILLE: XB9SX/XB12X/XB12XP/XB12SX 2.29 GENERAL sm00572 Figure 2-170. The headlamp grille is offered as a standard feature on the XB9SX, XB12SX, XB12X and XB12XP models to provide additional protection for the headlight assemblies. REMOVAL AND INSTALLATION Figure 2-170. Grab headlamp grille on either side and spread to remove from headlamp assemblies.
Page 207: Front Modules: Lightning And Ulysses Models
HOME FRONT MODULES: LIGHTNING AND ULYSSES MODELS 2.30 REMOVAL sm03875 Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect battery cables from battery: negative cable (black) first. See 1.16 BATTERY MAINTENANCE.
Page 208: Installation
HOME Attach front brake line p-clamp to rear of right front module sm03877 and tighten fastener to 36-60 in-lbs (4-6.8 Nm). Install ignition switch. See 6.3 IGNITION/HEADLAMP KEY SWITCH. Install connect instrument module. 6.25 INSTRUMENT MODULE. Connect turn signals. See 6.14 FRONT TURN SIGNALS.
Page 209: Handlebars: Firebolt
HOME HANDLEBARS: FIREBOLT 2.31 Install left switch gear housing. GENERAL Figure 2-175. Install grip and end cap (1). Firebolt handlebars are a clip-on assembly and are not adjustable. Install left clip-on into upper fork clamp (3) and tighten fastener (4) to 24-26 ft-lbs (32.5-35.3 Nm). REMOVAL Position clutch hand lever to rider preferences and tighten Right Clip-On...
Page 210: Handlebars: Lightning And Ulysses Models
HOME HANDLEBARS: LIGHTNING AND ULYSSES MODELS 2.32 Install clutch hand control. Tighten but do not torque. See REMOVAL 2.25 CLUTCH CONTROL. Remove seat. Install left switch housing. NOTE Check control wire routings. See D.1 APPENDIX D: HOSE On Ulysses Models, it will be necessary to disconnect and AND WIRE ROUTING.
Page 211 HOME sm03889a 1. End cap 2. Harness retainers 3. Clamp fasteners 4. Handlebar clamp 5. Left hand grip (XB12X models are OEM equipped with heated handgrips) 6. Handlebar (Ulysses models) 7. Handlebar (XB9SX, XB12SX) 8. Handlebar (XB12Scg, XB12Ss) 9. Clutch cable hook (Ulysses models) Figure 2-176.
Page 212: Mirrors
HOME MIRRORS 2.33 NOTES REMOVAL In a convex mirror, cars and other objects will look smaller Figure 2-177. Loosen adjuster nut (2) and remove and farther away than they actually are. Adjust mirrors to mirror (1) from mount (3). see a small portion of the riders shoulder in each mirror. This helps the rider establish the relative distance of Loosen mount (3) and remove from bracket (4).
Page 213: Footpeg, Heel Guard And Mount: Firebolt And Lightning Models
HOME FOOTPEG, HEEL GUARD AND MOUNT: FIREBOLT AND LIGHTNING MODELS 2.34 RIDER sm03637 REMOVAL Figure 2-178. Remove wear peg (7) from end of footpeg assembly. Remove clip (5). Remove footpeg pin (9). Remove footpeg (8). Remove heel guard fasteners (4). Remove heel guard (3).
Page 214: Installation
HOME INSTALLATION sm03837 Figure 2-179. Position footpeg mount (3) onto sub- frame tail assembly. Install footpeg mount (3). Using LOCTITE 271 tighten, fasteners (10) to 25-28 ft-lbs (33.9-38 Nm). Position heel guard (2) onto footpeg mounts (3). Install heel guard (2). Tighten heel guard fasteners to 72-96 in-lbs (8-10.8 Nm).
Page 215: Heel Guard And Footpeg Mounts: Ulysses Models
HOME HEEL GUARD AND FOOTPEG MOUNTS: ULYSSES MODELS 2.35 RIDER FOOTPEGS sm03636 Footpeg Removal Figure 2-180. Remove clip (3). Remove footpeg pin (8). Remove footpeg (10) and spring (9). Footpeg Installation Figure 2-180. Fit spring ends to footpeg mount and footpeg.
Page 216 HOME Install footpeg mount fasteners (2), and tighten to 132-144 HEEL GUARD REPLACEMENT in-lbs (15-16 Nm). Figure 2-183. If necessary, cut the rubber heel guard Install brake pedal fastener. See 2.11 BRAKE PEDAL. tabs on the inside of the footpeg mount to remove the heel guard.
Page 217: Sprocket Cover
HOME SPROCKET COVER 2.36 REMOVAL sm00123 Figure 2-184. Remove rear right chin fairing fasteners. Figure 2-185. Remove sprocket cover fasteners and washers (1, 3). INSTALLATION NOTE Apply LOCTITE 222 (purple) to long fastener (1) only. Figure 2-185. Install sprocket cover (2) using sprocket cover fasteners (1, 3) and tighten all fasteners and washers (1) to 12-36 in-lbs (1.4-4 Nm).
Page 218: Belt Guards
HOME BELT GUARDS 2.37 REMOVAL INSTALLATION Place a scissor jack under jacking point and raise rear Figure 2-186. Install upper belt guard (1) to swingarm wheel off ground. For location of jacking point see brace tightening fasteners (2) to 12-36 in-lbs (1.4-4.0 Nm). 4.19 EXHAUST SYSTEM.
Page 219: Intake Cover
HOME INTAKE COVER 2.38 REMOVAL INSTALLATION Figure 2-187. Position intake cover assembly (2) over NOTE top of air cleaner cover. Figure 2-187. The X-Guard (1) on XB9SX and XB12SX models is a non-replaceable part. NOTE Front fasteners are installed at a slight angle. Remove seat.
Page 220 HOME sm00656 1. X-Guard (XB9SX and XB12SX only) 2. Intake cover assembly 3. Rear intake cover fasteners with nylon washers (2) 4. Front intake cover fasteners with nylon washers (2) (models without translucid covers) 5. Front intake cover fasteners with top hat bushings (2) and isolating washers (4) (translucid covers only) Figure 2-187.
Page 221: Subframe Tail Assembly And Body Work: Firebolt
HOME SUBFRAME TAIL ASSEMBLY AND BODY WORK: FIREBOLT 2.39 Figure 2-188. Remove upper body work (1) from DISASSEMBLY subframe tail assembly (7). Remove seat and pillion. Remove body work fasteners (2). Disconnect passenger seat lock cable (6) by removing cable from seat lock plate (4) and ferrule from keylock Disconnect negative (-) battery cable first.
Page 222 HOME sm00657 Upper tail body work Subframe tail assembly fasteners Upper tail body work fasteners Lower tail body work Passenger seat lock Lower tail body work fasteners Passenger seat lock plate Trunk Passenger seat lock retainer Fastener Passenger seat lock cable License plate bracket Subframe tail assembly Passenger seat latch and fastener...
Page 223 HOME 17. Disconnect fuel pump connection and remove connector sm00432 from subframe tail assembly. See 4.14 FUEL PUMP. 18. Remove shock reservoir fasteners and feed the reservoir out of subframe tail assembly. See 2.23 REAR SHOCK ABSORBER. 19. See Figure 2-188.
Page 224 HOME Figure 2-189. Feed fuel vent hose (1) through tail sm00660 section, keeping the hose on top of rear shock reservoir hose. See D.1 APPENDIX D: HOSE AND WIRE ROUTING for hose and wire routing. 10. Install cable strap (3) holding shock reservoir hose, wire harness and fuel vent hose to subframe tail assembly.
Page 225 HOME Connect positive (+) battery cable first. If positive (+) cable After installing seat, pull upward on seat to be sure it is should contact ground with negative (-) cable connected, locked in position. While riding, a loose seat can shift the resulting sparks can cause a battery explosion, which causing loss of control, which could result in death or could result in death or serious injury.
Page 226: Left Tail Section And Battery Pan: Lightning Models
HOME LEFT TAIL SECTION AND BATTERY PAN: LIGHTNING MODELS 2.40 DISASSEMBLY Figure 2-192. Remove fuse block and relay center from support bracket. Remove seat. Move rear main harness and shock absorber reservoir to right side of vehicle. Remove left side passenger footrest support assembly. Disconnect negative (-) battery cable first.
Page 227 HOME sm00661a Main harness Fuse block and relay center Electronic Control Module Grounds (2) & Bat grd Bank angle sensor (BAS) connector [134] Battery negative cable Main harness grounds (2) (not shown) Battery positive cable Left and right trunk pan fasteners Rear brake light switch connector [121] Right tail section 6.
Page 228 HOME Figure 2-192. Connect: ASSEMBLY Wire harness ground (2) [GRD 2]. NOTE Rear brake light switch connector (5) [121]. Figure 2-193. There are two threaded plastic lugs (14) on the trunk pan that are used for manufacturing purposes only. ECM connectors (7) [10, 11] and [164] (on XB12 models).
Page 229 HOME is02466 1. Left and right tail section fastener to main frame/fuel tank assembly (4) 2. Right tail section 3. Center tail section 4. Center tail section fastener to rear tail section (4) 5. Left tail section 6. Ground terminal fastener (2) 7.
Page 230: Center Tail Section: Lightning Models
HOME CENTER TAIL SECTION: LIGHTNING MODELS 2.41 Install two fasteners (12) securing trunk pan to center tail DISASSEMBLY section but do not tighten. Remove seat. Apply LOCTITE 271 (red) to threads of left and right rear tail sections fasteners (4) and tighten to 102-114 in-lbs (11.5-12.8 Nm).
Page 231: Right Tail Section: Lightning Models
HOME RIGHT TAIL SECTION: LIGHTNING MODELS 2.42 DISASSEMBLY ASSEMBLY Remove seat. Figure 2-192. Install right tail section (16) onto vehicle. Install fastener (14) attaching right front trunk pan to right side tail section and tighten to 12-36 in-lbs (1.4- 4 Nm). Disconnect negative (-) battery cable first.
Page 232: Left And Right Tail Section: Ulysses Models
HOME LEFT AND RIGHT TAIL SECTION: ULYSSES MODELS 2.43 Remove seat. DISASSEMBLY/LEFT AND/OR RIGHT SIDE TAIL SECTION NOTES Disconnect negative (-) battery cable first. If positive (+) On XB12XT models, before removing left and/or right tail cable should contact ground with negative (-) cable con- section, it will be necessary to remove certain components nected, the resulting sparks can cause a battery explosion, of the luggage system.
Page 233 HOME sm00863b sm00547a Figure 2-195. Rear Brake Light Switch Connector (Ulysses) Remove fuse block and relay center. Remove main harness and grommet from battery pan. 1. Reservoir 2. Clamp Remove battery pan. 3. Remote reservoir hose Remove fasteners securing battery pan to left and 4.
Page 234 HOME Install shock reservoir, retainer and fastener. Tighten sm00666b fastener to 80-88 in-lbs (9.0-9.9 Nm). Install two fasteners securing the preload adjuster to the trunk pan and tighten to 36-60 in-lbs (4-6.8 Nm). Install battery pan: Install fasteners securing battery tray to left and right tail sections and tighten to 72-96 in-lbs (8-10.8 Nm).
Page 235 HOME sm00663 1. Fastener, washer and nut to main frame/fuel tank assembly (4) 2. Right tail section 3. Left tail section 4. Battery pan 5. Front trunk pan fastener to side tail section (2) 6. Ground terminal fastener (2) 7. Trunk pan assembly 8.
Page 236: Center Tail Loop: Ulysses Models
HOME CENTER TAIL LOOP: ULYSSES MODELS 2.44 Tighten nuts of left and right tail sections to 20-22 ft-lbs DISASSEMBLY (27.1-29.8 Nm). Repeat to verify torque. Remove seat. Connect: Right turn signal connector [18]. Left turn signal connector [19]. Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable con- License plate lamp connector [45].
Page 237 HOME sm00664 1. Tail loop 2. License plate bracket 3. Wire cover Figure 2-200. Wire Cover, Tail Loop and License Plate Bracket: Ulysses 2010 XB Service: Chassis 2-157...
Page 238: Trunk And Battery Pan: Ulysses Models
HOME TRUNK AND BATTERY PAN: ULYSSES MODELS 2.45 DISASSEMBLY TRUNK AND BATTERY PAN ASSEMBLY/TRUNK PAN AND BATTERY NOTE It will not be necessary to remove any part of the tail section Install the fan shroud. for this operation. Install the trunk pan. Remove seat.
Page 239: Sidestand
HOME SIDESTAND 2.46 GENERAL sm03932 This motorcycle does NOT have a locking sidestand. Park the motorcycle on a level, firm surface. An unbalanced motorcycle can fall, which could result in death or serious injury. (00122a) The sidestand is located on the left side of the motorcycle. The sidestand swings outward to support the motorcycle for parking.
Page 240 HOME Retract sidestand leg (9). sm05260 Install spring extension plate (2) and sidestand spring (1) using SNAP-ON SPRING TOOL (Part No. HE-52B). Extension plate should curve away from primary chain adjustment screw to allow for clearance around adjustment screw. INSTALLATION Figure 2-203.
Page 241: Front Fairing, Windshield, And Mirrors: Firebolt
HOME FRONT FAIRING, WINDSHIELD, AND MIRRORS: FIREBOLT 2.47 REMOVAL INSTALLATION Figure 2-205. Remove two center (4) and four side Figure 2-205. Position fairing (5) onto fairing support windscreen fasteners (3) to remove windshield (1). bracket and install turn signals (6, 7). See 6.14 FRONT TURN SIGNALS.
Page 242: Windshield And Windscreen: Lightning And Ulysses Models
HOME WINDSHIELD AND WINDSCREEN: LIGHTNING AND ULYSSES MODELS 2.48 Remove windscreen (4). LIGHTNING Installation Removal Figure 2-206. Position windscreen (4) onto left and NOTE right front modules (2, 5). Figure 2-206.The windscreen fasteners (3) extend through Install four fasteners (3) and tighten to 10-12 in-lbs (1.1- the left and right front modules (2, 5) and thread into the 1.4 Nm).
Page 243 HOME Remove six windscreen fasteners (5). ULYSSES XB12X Remove windscreen (6). Removal Installation NOTES Figure 2-207. Position windscreen (6) onto left and The windshield releases from the windscreen by pulling right front modules (2, 8) and the center fairing support outward and away from vehicle.
Page 244 HOME windscreen while both components are off motorcycle. ULYSSES XB12XT/XB12XP Lower fasteners can not be removed if windscreen is Removal installed on motorcycle. Remove windshield mounting hardware securing the NOTES windshield to the windscreen and pull windshield from Figure 2-208. Windshield MUST be removed from windscreen.
Page 245 HOME Align lower windscreen and windshield holes, For left and Installation right side lower holes, insert finish washer (4) and spacer Figure 2-208. Insert bodywork mount grommets (6) (5) onto screw (3) and place through windshield, grommet into lower holes in windscreen. and windscreen holes.
Page 246: Air Scoops
HOME AIR SCOOPS 2.49 RAM AIR SCOOP ENGINE SHROUD AIR SCOOP Removal Removal Figure 2-209. On right side of motorcycle, locate NOTE engine shroud air scoop (6). When removing and installing the left air scoop, the alternator and voltage regulator harnesses and connections are secured Remove three engine shroud air scoop fasteners (5).
Page 247 HOME sm00124a Oil cooler air scoop fastener and washer (2) Ram air scoop Oil cooler air scoop Screw, stainless, button head (3), Ulysses Ram air scoop fastener and washer Ram air scoop, inner, Ulysses Engine shroud air scoop Ram air scoop, outer, Ulysses Engine shroud air scoop fastener and washer (3) Fan shroud, Ulysses Figure 2-209.
Page 248 HOME RAM AIR SCOOP AND FAN SHROUD: Installation ULYSSES Install fan shroud. See Figure 2-210 Removal sm06807 Figure 2-209. Remove fasteners securing the outer ram air scoop to the inner ram air scoop. NOTE After removing fasteners securing the inner ram air scoop to the fuel tank/frame, it will be necessary to detach the Oxygen Sensor connector from the inside of the scoop.
Page 249 HOME Connect positive (+) battery cable first. If positive (+) cable After installing seat, pull upward on seat to be sure it is should contact ground with negative (-) cable connected, locked in position. While riding, a loose seat can shift the resulting sparks can cause a battery explosion, which causing loss of control, which could result in death or could result in death or serious injury.
Page 250: Chin Fairing
HOME CHIN FAIRING 2.50 Align left section (3) and loosely install left side fasteners REMOVAL and washers (4). Turn wheel full right or left for easier access to center Tighten all fasteners to 36-48 in-lbs (4-5.4 Nm). fasteners. Figure 2-211. Remove center section fasteners and washers (2).
Page 251: Seat
HOME SEAT 2.51 FIREBOLT Pillion Rider Seat NOTE The trunk is located under the pillion. Figure 2-212. Peel up rear corners of seat and remove two fasteners. Figure 2-214. Insert ignition key into the pillion lock located on the left side of motorcycle. Turn key clockwise Pull seat back over tail section and remove.
Page 252 HOME pd00242 om00339 1. Seat hooks (2) Figure 2-215. Seat Lock Location: Lightning Models 2. Seat latch 3. Tab Figure 2-217. Seat Mounting Points: XB9SX/XB12SX/XB12Scg om01428 pd00230 1. Seat hooks (4) Figure 2-216. Seat Removal: Lightning Models 2. Seat latch 3.
Page 253 HOME Figure 2-222. Grip rear of seat and pull toward rear pd00187 of motorcycle to remove. om00576 Figure 2-221. Seat Lock: Ulysses Models om00574 1. Seat hooks 2. Tab Figure 2-219. Fitting Seat Hooks to Frame Mounting Posts om00054 Figure 2-222. Seat Removal: Ulysses Models Installation Figure 2-223.
Page 254 HOME om00573 1. Seat hook 2. Seat lock latch 3. Front tab Figure 2-223. Seat Tab/Hooks: Ulysses Models 2-174 2010 XB Service: Chassis...
Page 255: Seat Locks
HOME SEAT LOCKS 2.52 NOTES LIGHTNING Once seat lock has been started through the hole in the Removal trunk pan and plate, now is the time to connect the cable end to the seat lock. Remove seat. Seat lock plate must be aligned to tab on seat lock for Cut cable strap loosely securing BAS wiring harness to proper installation.
Page 256 HOME sm00689 Seat lock Retainer Plate Cable end Retainer Latch Cable end Latch bracket Cable Trunk pan 6. Latch screw Figure 2-224. Seat Lock Assembly: Lightning REMOVAL: ULYSSES MODELS Remove seat lock: Remove wire cover from bottom side of license plate Remove seat.
Page 257 HOME Install the seat lock (1) into license plate bracket and plate sm03841 (2). NOTES Once seat lock has been started through the hole in the license plate bracket and plate (2), now is the time to connect the cable end to the seat lock. Seat lock plate must be aligned to tab on seat lock for proper installation.
Page 258 HOME Remove seat lock lever (4) by removing fastener (2) and washer (3) from seat lock (7). Remove spring (5). After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift Remove seat lock clip (1) by sliding from seat lock plate causing loss of control, which could result in death or (6).
Page 259: Triple Tail: Ulysses Models
HOME TRIPLE TAIL: ULYSSES MODELS 2.53 the upright position, it is a passenger backrest (2) with subtle GENERAL flex for passenger comfort. When in the rearward position, you Figure 2-227. The Triple Tail when folded forward acts as can carry a passenger and have a luggage rack (3) for extra a luggage rack (1) with integrated tie-down hooks.
Page 260 HOME Using a Snap-on seal and bushing driver, tap in the Holding the rack, fit the RH grab handle (2) unto the front bearing. fastener and install the rear fastener. Do not tighten. Tighten front and rear fasteners to the following specifica- INSTALLATION tions: Figure...
Page 261: Luggage: Xb12Xt
HOME LUGGAGE: XB12XT 2.54 REMOVAL: SIDE CASE NOTES The side cases and brackets may be removed without removing the top case and bracket. This procedure is recommended for service only. The vehicle should never Do not exceed the motorcycle's Gross Vehicle Weight be operated with just the top case in place.
Page 262 HOME Figure 2-229. Place key in side case locking latch sm05145 (12), on front surface of side case, in open position. Open latch. Remove side case by pulling away from vehicle. Remove fastener (10) securing the side case bracket (11) to the back of the passenger footrest support bracket.
Page 263 HOME Tighten the two fasteners (6) attaching the top case sm05204 mounting bracket (2) to the grab handles (5) to 19-20 ft- lbs (25.8-27.1 Nm). Tighten all remaining fasteners to 96-120 in-lbs (10.8-13.6 Nm). LUGGAGE CASE LATCH MECHANISM Removal Open desired case in order to access the latch mechanism for replacement.
Page 264 HOME sary to lift the lid gasket above the middle of latch and out of Figure 2-234. Loosen large hex nut and remove lock the way. from latch mechanism. Figure 2-232. Remove and discard two Phillips head Installation screws from existing latch mechanism. Figure 2-234.
Page 265: Luggage: Xb12Xp
HOME LUGGAGE: XB12XP 2.55 top case in place. This would result in a high stress situ- SIDE CASE ation on the left and right tailsection castings. Removal This operation should be performed for one side case bracket at a time. It does not matter which side case bracket is removed first.
Page 266 HOME NOTES Installation The lock assembly is non-replaceable. If it is determined NOTE that a new lock is needed, the entire side case latch To make sure you have proper alignment of side case brackets, mechanism must now be replaced. always loosen the passenger peg support bracket fasteners Figure 2-236.
Page 267 TABLE OF CONTENTS SUBJECT..........................PAGE NO. 3.1 FASTENER TORQUE VALUES....................3-1 3.2 SPECIFICATIONS........................3-3 3.3 ENGINE.............................3-7 3.4 ENGINE ROTATION FOR SERVICE..................3-9 3.5 ENGINE REMOVAL.........................3-14 3.6 ENGINE INSTALLATION......................3-24 3.7 CYLINDER HEAD........................3-35 3.8 CYLINDER AND PISTON......................3-51 3.9 OILING SYSTEM........................3-60 3.10 OIL PUMP..........................3-61 3.11 OIL RESERVOIR AND OIL HOSE ROUTING...............3-67 3.12 OIL LINE FITTINGS......................3-69 3.13 OIL COOLER.........................3-71 3.14 OIL PRESSURE INDICATOR SWITCH.................3-72...
Page 268 NOTES...
Page 269: Fastener Torque Values
HOME FASTENER TORQUE VALUES FASTENER TORQUE VALUES IN THIS CHAPTER The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE NOTES Air scoop fastener at oil cooler 48-72 in-lbs 5.4-8 Nm 3.13 OIL COOLER, Installation/LOCTITE 271 (red) Anti-rotation screws (lifter) 55-65 in-lbs 6-7 Nm...
Page 270 HOME FASTENER TORQUE VALUE NOTES Oil pressure signal light switch 96-120 in-lbs 10.8-13.6 Nm 3.14 OIL PRESSURE INDICATOR SWITCH, Oil Pressure/LOCTITE 565 HIGH PERFORMANCE PIPE SEALANT WITH TEFLON Oil pump body and cover fasteners 100-120 in-lbs 11.3-13.6 Nm 3.10 OIL PUMP, Assembly/Installation Oil pump body and cover fasteners 108-156 in-lbs 12.2-17.6 Nm...
Page 271: Specifications
HOME SPECIFICATIONS not given under SERVICE WEAR LIMITS, see NEW COMPON- GENERAL ENTS. NOTE Service wear limits are given as a guideline for measuring components that are not new. For measurement specifications Table 3-1. General Engine Specifications ITEM SPECIFICATION Type 2 cylinder, air cooled, four-stroke 45 degree V-twin Compression ratio 10:1...
Page 272 HOME Table 3-4. Valve Spring Specifications VALVE SPRING NEW COMPONENTS SERVICE WEAR LIMITS Exhaust 1.850 in. (closed) 135 lbs 61.2 kg Exhaust 1.300 in. (open) 312 lbs 141.5 kg Table 3-5. Rocker Arm Specifications ROCKER ARM NEW COMPONENTS SERVICE WEAR LIMITS Shaft fit in bushing (loose) 0.0005-0.0020 in.
Page 273: Hydraulic Lifters
HOME Table 3-9. Connecting Rod Specifications CONNECTING ROD NEW COMPONENTS SERVICE WEAR LIMITS Piston pin fit (loose) 0.00145-0.00155 in. 0.03683-0.03937 mm 0.00200 in. 0.0508 mm Side play between flywheels 0.005-0.031 in. 0.1-0.8 mm 0.036 in. 0.9 mm Fit on crankpin (loose) 0.0004-0.0017 in.
Page 274 HOME Table 3-14. Pinion Shaft (Right Main) Bearing Specifications PINION SHAFT BEARINGS NEW COMPONENTS SERVICE WEAR LIMITS Bearing running clearance 0.00012-0.00086 in. 0.003-0.022 mm Fit in oil pump body bore. 0.0023-0.0043 in. 0.058-0.109 mm 0.0050 in. 0.127 mm Table 3-15. Sprocket Shaft Bearing Specifications ITEM SPECIFICATION (INTERFERENCE FIT) Outer race fit in crankcase (tight)
Page 275: Engine
Use a CYLINDER LEAKDOWN TESTER (Part No. HD-35667A) COMPRESSION TEST and follow the instructions supplied with the tester. The following are some general instructions that apply to Buell PART NUMBER TOOL NAME motorcycle engines:...
Page 276 HOME Refer to Table 3-17. Listen for air leaks at induction intake, DIAGNOSING SMOKING ENGINE OR HIGH exhaust and head gasket. OIL CONSUMPTION NOTE Perform the Compression Test. See 3.3 ENGINE, Compression If air is escaping through valves, check push rod length. Test.
Page 277: General
HOME ENGINE ROTATION FOR SERVICE Remove seat and disconnect battery cables from battery: GENERAL negative cable (black) first. The following process allows you to rotate engine down, Remove intake cover. See 2.38 INTAKE COVER. pivoting on rear isolator mount, in order to service components in the top end.
Page 278 HOME sm03746a Coil IAC sensor connection [87] Coil connection [83] Fuel line connection Coil wire harness retaining clip Throttle position sensor connection [88] Throttle cables IAT sensor [89] Fuel pressure sensor Engine temperature sensor connection [90] Fuel injector connections [84 & 85] Oxygen sensor connection [137] Figure 3-1.
Page 279 HOME sm00701 Frame assembly Washers for center tie bar mount (2) "V" bracket Center tie bar assembly Fasteners for "V" bracket (3) Fasteners for center tie bar assembly (2) Front isolator assembly Washers for center tie bar assembly (2) Fasteners (2) Ground strap Bolt Rear isolator assembly...
Page 280 HOME NOTE Figure 3-2. Insert front isolator bolt (6) through front Cut the two cable straps securing the crank position sensor isolator (4) and loosely thread into frame. Do not tighten (CKP) wire to the "V" bracket. at this point. 21.
Page 281 HOME 20. Install idler pulley. See 5.7 DRIVE BELT AND IDLER sm04534 PULLEY. 21. Install left and right side rider footpeg mount. See 2.34 FOOTPEG, HEEL GUARD AND MOUNT: FIREBOLT AND LIGHTNING MODELS 2.35 HEEL GUARD AND FOOTPEG MOUNTS: ULYSSES MODELS.
Page 282: Engine Removal
HOME ENGINE REMOVAL NOTE DISASSEMBLY When removing the left air scoop, the alternator and voltage NOTES regulator harnesses and connections are secured to the bottom of the air scoop with three cable straps. When removing the Vehicle should be placed onto the lift with rear tire in the right air scoop/shroud it will be necessary to remove the front wheel vise in order to successfully perform this procedure.
Page 283 HOME sm03746a Coil IAC sensor connection [87] Coil connection [83] Fuel line connection Coil wire harness retaining clip Throttle position sensor connection [88] Throttle cables IAT sensor [89] Fuel pressure sensor Engine temperature sensor connection [90] Fuel injector connections [84 & 85] Oxygen sensor connection [137] Figure 3-5.
Page 284 HOME 22. Disconnect clutch cable. 23. See Figure 3-9. Remove front "V" bracket with oil cooler from main frame. Slide clutch cable adjuster boot (2) up to access clutch adjuster. Disconnect alternator connector [46] (1) and voltage regulator connector [77] (2) in order to remove the Loosen clutch adjuster to release tension from hand "V"...
Page 285 HOME 30. See Figure 3-8. Remove vent oil line (11). 32. Remove return oil line (7). Remove clamp (12) in front of starter securing vent Remove p-clamp (8) at swingarm/oil reservoir (10). oil line to return oil line. Disconnect oil return line (7) at swingarm/oil reservoir Disconnect vent oil line from oil pump.
Page 286 HOME sm03729 Oil pump P-clamp Oil cooler return line to crankcase Rear muffler bracket Oil cooler feed line from oil pump Swingarm/Oil reservoir Oil filter Vent oil line Front muffler mount Oil line clamp Feed oil line Cable, interactive exhaust Return oil line Drain plug Figure 3-8.
Page 287 HOME sm00701 Frame assembly Washers for center tie bar mount (2) "V" bracket Center tie bar assembly Fasteners for "V" bracket (3) Fasteners for center tie bar assembly (2) Front isolator assembly Washers for center tie bar assembly (2) Fasteners (2) Ground strap Bolt Rear isolator assembly...
Page 288 HOME sm03744 sm03933 1. Neutral switch connection [131] 2. Oil pressure indicator switch wire 3. Interactive exhaust cable Figure 3-10. Electrical Connectors and Interactive Exhaust Cable Under Sprocket Cover 33. Remove front and rear muffler brackets. 34. See Figure 3-11. Remove two fasteners (2) and remove sidestand assembly.
Page 289 HOME sm03741 sm00730 Figure 3-14. Transmission Vent Line: Firebolt Figure 3-12. Supporting Vehicle for Disassembly 36. See Figure 3-9. Remove front isolator bolt (6). Remove front isolator assembly fasteners (5). sm00737 37. See Figure 3-13. Remove: Rear isolator bolt (1). Swingarm pivot shaft (2).
Page 290 HOME 41. Remove engine. sm03745 sm00739 1. Left side 2. Right side Figure 3-19. Front Exhaust Mount Bushings (2 piece) Figure 3-17. Center Tie Bar Mount sm02996 42. Once engine has been removed from vehicle, finish removing the following items as required: Shifter assembly.
Page 291 HOME 43. See Figure 3-21. If the crankcases are being separated it sm03731 will be necessary to remove rear isolator assembly by removing the forward two fasteners first and then the two rear fasteners (install with new fasteners). 44. See Figure 3-22.
Page 292: Engine Installation
HOME ENGINE INSTALLATION NOTE ASSEMBLY Hand thread pivot shaft into crankcase prior to installing Engine Preparation for Re-installation the threaded insert. Remove pivot shaft after installing the threaded insert. NOTE Figure 3-26. Apply LOCTITE 242 (blue) to Install components that were removed from engine as were swingarm pivot shaft pinch bolt threaded insert and necessary for service prior to installing engine in frame.
Page 293 HOME Install transmission vent line. Installing Engine in Frame Figure 3-30. On Firebolt models, route transmis- NOTES sion vent line up through left side of frame exiting Vehicle should be placed onto the lift with rear tire in the under the rear master cylinder under the rider's seat. wheel vise in order to successfully perform this procedure.
Page 294 HOME Figure 3-33. Using the overhead hoist to align the is06235 frame to the rear isolator, install rear isolator bolt and leave loose at this time. sm02952b Figure 3-32. Trim Transmission Vent Hose Figure 3-33. Rear Isolator Bolt 3-26 2010 XB Service: Engine...
Page 295 HOME sm00701 Frame assembly Washers for center tie bar mount (2) "V" bracket Center tie bar assembly Fasteners for "V" bracket (3) Fasteners for center tie bar assembly (2) Front isolator assembly Washers for center tie bar assembly (2) Fasteners (2) Ground strap Bolt Rear isolator assembly...
Page 296 HOME NOTES Figure 3-35. Insert front isolator bolt (3) through front Exhaust header must be tightened with the engine rotated isolator (1) and loosely thread into frame. Do not tighten in the down position. It is not possible to reach fasteners at this point.
Page 297 HOME sm00636a Rear muffler strap fastener (2) Front muffler mount fastener Rear muffler strap (2) Front muffler mount bushings Interactive muffler (XB12 models) Interactive exhaust cable Muffler (XB9 models) Rear muffler bracket Front muffler strap Rear muffler bracket fasteners (2) Front muffler strap fastener Symbol for jacking point on muffler (located on 7.
Page 298 HOME sm03729 Oil pump P-clamp Oil cooler return line to crankcase Rear muffler bracket Oil cooler feed line from oil pump Swingarm/Oil reservoir Oil filter Vent oil line Front muffler mount Oil line clamp Feed oil line Cable, interactive exhaust Return oil line Drain plug Figure 3-37.
Page 299 HOME 23. Install p-clamp (8) on return oil line (7) at the swingarm/oil 26. Install oil cooler feed line (3) and oil cooler return line (2). reservoir and tighten fastener to 40-50 in-lbs (4.5-5.6 Nm). NOTE 24. Install the vent oil line (11) in the same manner as the Figure 3-38.
Page 300 HOME 31. Install muffler. See 4.19 EXHAUST SYSTEM. sm05389 32. Install drive belt and idler pulley. See 5.7 DRIVE BELT AND IDLER PULLEY. 33. Install left and right side rider footrests and support plates. 2.34 FOOTPEG, HEEL GUARD AND MOUNT: FIREBOLT AND LIGHTNING MODELS 2.35 HEEL GUARD AND FOOTPEG MOUNTS: ULYSSES...
Page 301 HOME sm03746a Coil IAC sensor connection [87] Coil connection [83] Fuel line connection Coil wire harness retaining clip Throttle position sensor connection [88] Throttle cables IAT sensor [89] Fuel pressure sensor Engine temperature sensor connection [90] Fuel injector connections [84 & 85] Oxygen sensor connection [137] Figure 3-41.
Page 302 HOME Connect positive (+) battery cable first. If positive (+) cable After installing seat, pull upward on seat to be sure it is should contact ground with negative (-) cable connected, locked in position. While riding, a loose seat can shift the resulting sparks can cause a battery explosion, which causing loss of control, which could result in death or could result in death or serious injury.
Page 303: Removal
HOME CYLINDER HEAD REMOVAL sm00131 Before removing the cylinder head assembly, it is necessary to rotate engine down as described in 3.4 ENGINE ROTATION SERVICE. The rocker arm covers and internal compon- ents must be removed before removing cylinder heads. NOTE All washers and fasteners used in the engine are hardened.
Page 304 HOME sm00130 Crankcase breather Gasket (lower) Screw, tappet anti-rotation (2) Grommet Rocker arm shafts Gasket (push rod cover) Screw (4) Screw (2) Push rod cover Washer (4) Washer (2) Screw (4) Fiber seal (4) Rocker cover (lower) O-ring (push rod cover - 2) Rocker cover (top) Rocker arm (2) Push rod...
Page 305 HOME Cylinder Head Assemblies sm00133 NOTE Figure 3-45. Distortion to the head, cylinder and crankcase studs may result if head screws are not loosened (or tightened) gradually in the sequence shown. Loosen each head screw 1/8-turn following the sequence shown. Continue loosening in 1/8-turn increments until screws are loose.
Page 306 HOME sm00134 Figure 3-46. Valve Spring Compressor 3-38 2010 XB Service: Engine...
Page 307 HOME sm00135 Screw Valve guide intake and exhaust Cylinder base gasket Screw Cylinder base stud Valve collar retainer Cylinder head Exhaust valve Upper valve spring collar Exhaust port stud Exhaust valve seat Valve spring Cylinder head gasket Valve seal and lower valve Cylinder insert spring collar assembly 12.
Page 308: Cleaning And Inspection
HOME Measure and record rocker arm shaft diameter. CLEANING AND INSPECTION Figure 3-49. Measure where shaft fits in lower PART NUMBER TOOL NAME rocker arm cover. B-45525 VALVE GUIDE HONE Figure 3-50. Measure where rocker arm bushings HD-34751 VALVE GUIDE CLEANING BRUSH ride.
Page 309 HOME Inspect for burrs around the valve stem keeper groove. sm00140 Remove burrs with a fine tooth file if found. Valve Seats NOTE Valve seats are also subject to wear. Resurface valve seats whenever valves are refinished. Inspect seats for cracking, chipping or burning. Replace seats if any evidence of these conditions are found.
Page 310 HOME Valve Springs sm00144 Inspect valve springs for broken or discolored coils. NOTE A single valve spring is used for each valve. The inner and outer springs are combined into one tapered spring that is progressively wound. Figure 3-54. Check free length and compression force of each spring.
Page 311 HOME REPLACING VALVE GUIDES sm00145 PART NUMBER TOOL NAME B-45523 VALVE GUIDE REAMER B-45524-A VALVE GUIDE REMOVER/INSTALLER B-45525 VALVE GUIDE HONE HD-34751 VALVE GUIDE CLEANING BRUSH Valve guide replacement, if necessary, must be done before valve seat is ground. It is the valve stem hole in valve guide that determines seat grinding location.
Page 312 HOME to be used and subtract 0.080 in. (2.032 mm) from that PROCEDURE FOR USING THE NEWAY number. VALVE SEAT CUTTER Set your dial caliper to the lesser measurement and lock PART NUMBER TOOL NAME down for quick reference. This is the location of your valve seat.
Page 313 HOME 11. When you accomplish a complete clean-up of the 46° angle and the width is at least 0.062 in. (1.575 mm), pro- ceed to the next step. Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear 12.
Page 314 HOME sm00149 sm00134 Figure 3-60. Valve Guide Seal Protector Sleeve sm00150 Figure 3-63. Valve Spring Compressor PUSH ROD COVER INSTALLATION Figure 3-65. Install push rod covers. Install new O-rings (2) on top of each push rod cover (3). NOTE Before installing O-rings on the top of each pushrod cover be sure to apply a small amount of clean engine oil to each O-ring.
Page 315 HOME NOTE sm00153 After head(s) have been installed do not turn engine over until both push rods can be turned with fingers. Otherwise, damage to push rods or rocker arms may result. Table 3-19. Push Rod Selection POSITION COLOR LENGTH CODES Exhaust 1 Band...
Page 316 HOME NOTE 12. See Figure 3-69. Install upper rocker covers (6). The procedure for tightening the head screws is critical to Place a new inner gasket (9) on lower rocker box proper distribution of pressure over gasket area. It prevents assemblies.
Page 317 HOME sm00154 sm00131 1. Screws and washers 2. Bolts and washers Figure 3-67. Tightening Head Screws 3. Rocker arm fasteners Figure 3-68. Lower Rocker Box Fasteners 2010 XB Service: Engine 3-49...
Page 318 HOME sm00130 Crankcase breather Gasket (lower) Screw, tappet anti-rotation (2) Grommet Rocker arm shafts Gasket (push rod cover) Screw (4) Screw (2) Push rod cover Washer (4) Washer (2) Screw (4) Fiber seal (4) Rocker cover (lower) O-ring (push rod cover - 2) Rocker cover (top) Rocker arm (2) Push rod...
Page 319: Cylinder And Piston
HOME CYLINDER AND PISTON REMOVAL/DISASSEMBLY sm00155 PART NUMBER TOOL NAME HD-34623C PISTON PIN RETAINING RING INSTALLER Strip motorcycle as described under 3.4 ENGINE ROTA- TION FOR SERVICE. Remove cylinder head. See 3.7 CYLINDER HEAD. Clean crankcase around cylinder base to prevent dirt and debris from entering crankcase while removing cylinder.
Page 320 HOME the piston could score the cylinder during engine operation and sm00157 cause engine damage. sm00156 Figure 3-72. Piston Pin and Piston Identification NOTE Figure 3-72. The arrows on the pistons must always point toward the front of the engine. sm00158 1.
Page 321 HOME Soak cylinder and piston in an aluminum-compatible Figure 3-74. Check cylinder head gasket surface for cleaner/solvent until deposits are soft, then clean with a flatness. brush. Blow off loosened carbon and dirt particles and Lay a straightedge across the surface. wash in solvent.
Page 322 HOME NOTE Starting at the bottom of the cylinder, move the deglazing If cylinder clearance exceeds service wear limit, cylinders and tool up and down the entire length of the cylinder bore for pistons should be replaced with new components. See 10 to 12 complete strokes.
Page 323 HOME sion ring, then the top ring. Use TRANSMISSION SHAFT sm00162 RETAINING RING PLIERS (Part No. J-5586-A) to slip compression rings over piston into their respective grooves. Be extremely careful not to over expand, twist rings or damage piston surface when installing rings. NOTE Install second compression ring with dot towards top.
Page 324 HOME CONNECTING ROD BUSHING sm00163 PART NUMBER TOOL NAME HD-35102 WRIST PIN BUSHING HONE HD-94800-26A REAMER HD-95952-33C CONNECTING ROD CLAMPING TOOL HD-95970-32D PISTON PIN BUSHING TOOL When connecting rod bushing is worn to excessive pin clear- ance 0.002 in. (0.051 mm) or more, it must be replaced. Figure 3-81.
Page 325 HOME sm03828 sm00165 1. Remover side of driver 2. Receiver cup Figure 3-81. Connecting Rod Clamping Tool Figure 3-83. Removing Wrist Pin Bushing sm00166 sm03829 Figure 3-84. Installer Side of Driver 1. Hex cylinder 2. Threaded rod 3. Flat washer ASSEMBLY/INSTALLATION 4.
Page 326 HOME if it has been installed and then removed for any reason. A sm00157 loosely installed ring will come out of the piston groove and damage cylinder and piston beyond repair. Figure 3-87. Install new piston pin retaining rings (1) using PISTON PIN RETAINING RING INSTALLER (Part No.
Page 327 HOME sm00163 sm00171 1. Piston ring compressor Figure 3-89. Compressing Piston Rings 1. Front 2. Rear 3. Piston pin 4. Position ring end gaps at arrows (minimum of 90 degrees apart) Figure 3-88. Ring End Gap Position 2010 XB Service: Engine 3-59...
Page 328: Oiling System
HOME OILING SYSTEM 10. Oil flow then continues to the main feed galley at the top GENERAL of the oil pump body. Passages in the crankcase intersect The engine has a gravity/suction type oiling system, the main feed galley and carry oil to all hydraulic lifters incorporating oil feed and return pumps in the same body and piston jets.
Page 329: Oil Pump
HOME OIL PUMP 3.10 The oil pump seldom needs servicing. Before you disassemble GENERAL an oil pump suspected of not producing adequate oil pressure, Figure 3-90. The oil pump consists of two gerotor gear be sure that all possible related malfunctions have been elim- sets, feed and return, housed in one pump body.
Page 330 HOME sm02940a Oil pump cover Oil pump body Oil pump cover gasket Oil pump mounting gasket Separator plate Oil pump mounting screws (4) Scavenge gerotor gear set Oil pressure indicator switch Feed gerotor gear set Pressure relief valve Oil line fittings (4) Oil pump cover screws (7) 7.
Page 331 HOME NOTES Disconnect the vent oil line connection (4) from the top Oil pump can be removed with engine in frame. left side of the oil pump body. Before removing the oil pump body it will be necessary to 10. Disconnect the oil cooler return line from the oil pump. unload the valve train to relieve pressure on the cam 11.
Page 332 HOME SM03730 Feed oil line Return oil line from oil cooler Return oil line Feed oil line to oil cooler Oil pump cover Oil pressure switch Vent oil line Pressure relief valve 5. Oil pump body Figure 3-91. Oil Pump Connections CLEANING AND INSPECTION Clean all parts in cleaning solvent.
Page 333 HOME Figure 3-92. Inspect both gerotor sets for wear. Install oil pressure switch and tighten to 96-120 in-lbs (10.8-13.6 Nm). Mesh pieces of each set together as shown. Install hydraulic lifters push rods. Use a feeler gauge to determine clearance. 3.16 HYDRAULIC LIFTERS, Installation.
Page 334 HOME sm03727 Figure 3-94. Oil Pump Body and Cover Mounting Screw Torque Sequence 3-66 2010 XB Service: Engine...
Page 335: Oil Reservoir And Oil Hose Routing
HOME OIL RESERVOIR AND OIL HOSE ROUTING 3.11 The oil cooler feed line (3) exits the front of the oil pump and GENERAL routes across the front of the engine to the oil cooler on the Figure 3-95. Engine oil runs through the swingarm which left front side of the crankcases.
Page 336 HOME sm03729 Oil pump P-clamp Oil cooler return line to crankcase Rear muffler bracket Oil cooler feed line from oil pump Swingarm/Oil reservoir Oil filter Vent oil line Front muffler mount Oil line clamp Feed oil line Cable, interactive exhaust Return oil line Drain plug Figure 3-95.
Page 337: Installation
HOME OIL LINE FITTINGS 3.12 REMOVAL sm00206 PART NUMBER TOOL NAME B-41623-B OIL LINE REMOVER Figure 3-96. Close the OIL LINE REMOVER (Part No. B-41623-B) over the oil line. Match the notches in the tool flange to the U-bends in the spring clip. Figure 3-97.
Page 338 HOME sm00207 Figure 3-98. Flanged Oil Line 3-70 2010 XB Service: Engine...
Page 339: Oil Cooler
HOME OIL COOLER 3.13 GENERAL REMOVAL For engine oil flow through the engine, See 3.9 OILING Cover the front chin fairing to protect finish. SYSTEM. NOTE Engine oil flows from the oil pump to the oil cooler through a Dispose of oil in accordance with local regulations. supply hose.
Page 340: Oil Pressure Indicator Switch
HOME OIL PRESSURE INDICATOR SWITCH 3.14 GENERAL sm03000 The oil pressure indicator switch is a pressure-actuated dia- phragm-type switch. When oil is not circulating through the system or when oil pressure is low, spring tension holds the switch contacts closed, thereby completing the signal light cir- cuit and causing the indicator lamp to illuminate.
Page 341 HOME engine to reach operating temperature of 180° F (82° C) Start engine and test oil pressure switch for proper opera- tion. Check oil pressure switch for leaks. At 3000 RPM, oil pressure will vary from 20-28 psi (138-193 kPa). sm05397 At idle speed (1050-1150 RPM), oil pressure will vary from 10-16 psi (69-110 kPa).
Page 342: Crankcase Breathing System
HOME CRANKCASE BREATHING SYSTEM 3.15 GENERAL sm00216 Figure 3-102. Pressure created in the flywheel area on piston downstroke is released through the reed valve into the gearcase. From there a mixture of crankcase air and oil mist is vented up the push rod covers to the upper rocker box. Figure 3-103.
Page 343 HOME With the lower part of the curve on the reed valve stop (2) If it was necessary to replace the reed block, apply LOC- facing out, apply LOCTITE 222 (purple), install and tighten TITE 222 (purple), install the fasteners and tighten to 25-35 fastener to 5-7 in-lbs (0.6-0.8 Nm).
Page 344: Hydraulic Lifters
HOME HYDRAULIC LIFTERS 3.16 GENERAL REMOVAL Figure 3-106. The lifter assembly consists of a hydraulic lifter and roller. The lifter and roller, under compression force from valve spring, follow the surface of the revolving cam. The Compressed air can pierce the skin and flying debris from up-and-down motion produced is transmitted to the valve by compressed air could cause serious eye injury.
Page 345 HOME Check lifter roller end clearance. sm00173 End clearance should be within 0.008-0.022 in. (0.203-0.559 mm). Replace lifters if clearance exceeds SERVICE WEAR LIMIT of 0.026 in. (0.660 mm). Soak lifters in clean engine oil. Keep covered until assembly. INSTALLATION Figure 3-107.
Page 346: Gearcase And Cam Gears
HOME GEARCASE AND CAM GEARS 3.17 For the gearcase components to operate at their optimum, all GENERAL components must be properly fitted and matched. Changing Read the complete gearcase section carefully before you begin one component can affect many others. It is important to know any service work.
Page 347: Removal And Disassembly
HOME Check for minimum cam gear end play. Record readings. REMOVAL AND DISASSEMBLY Remove oil pump. See 3.10 OIL PUMP. Figure 3-110. Rotate crankshaft until all timing marks (7, 8) are aligned as shown. Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury.
Page 348: Cam And Pinion Gear Identification, Inspection And Selection
HOME ASSEMBLY AND INSTALLATION PART NUMBER TOOL NAME Compressed air can pierce the skin and flying debris from HD-43984 CRANKSHAFT LOCKING TOOL compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never Figure 3-112. Install pinion gear spacer and pinion use your hand to check for air leaks or to determine air gear on pinion shaft.
Page 349 HOME Install oil pump body and all gears and onto right crank- sm02987 case half, install fasteners and tighten. See 3.10 OIL PUMP. Figure 3-114. Check cam gear end play for each cam gear as follows: Turn engine over until lobe of cam gear being checked is pointing toward its respective tappet guide hole.
Page 350: Crankcase
HOME CRANKCASE 3.18 Remove starter motor. See STARTER. GENERAL Figure 3-115. Remove rear isolator assembly by When rod bearings, pinion shaft bearing, or sprocket shaft removing the forward two fasteners first and then the two bearing are in need of repair, the engine must be removed rear fasteners (re-install with new fasteners).
Page 351: Oil Filter Adapter
HOME sm00176 1. Crankcase fasteners 2. Crankcase fastener behind shifter mechanism Figure 3-116. Crankcase Fasteners OIL FILTER ADAPTER NOTE The oil filter adapter has identical ends. Either end may be installed into the filter mount. Figure 3-117. Remove the oil filter adapter from the oil filter mount.
Page 352: Piston Jets
HOME sm03862 sm02980 Figure 3-118. Piston Oil Jet Assemblies Installation NOTES Gaskets that are missing, distorted, pinched or otherwise damaged will result in either oil leakage or low oil pressure. Gasket is part of the piston jet assembly. Gasket not sold separately.
Page 353 HOME sm02981 Figure 3-119. Removing Flywheels from Left Crankcase sm02942 14 13 Spacer, sprocket shaft Thrust washer Retaining ring, oil seal Connecting rod and flywheel assembly Oil seal Inner race Thrust washer Pinion shaft bearing Crankcase half Retaining ring Bearing, sprocket shaft Outer bearing race Bearing retaining ring Crankshaft case...
Page 354: Pinion Shaft Bearing
HOME sm00182 sm00184 Figure 3-123. Direction of Bearing Removal From Left Crankcase NOTE Figure 3-121. Sprocket Shaft Seal Retaining Ring The bearing presses to the inside. There is a shoulder incor- porated into the left crankcase half which allows the bearing to be removed in one direction only.
Page 355 HOME is based on the largest measured outside diameter (OD) of the sm00186 inner race and the smallest measured inside diameter (ID) of the outer race (crankcase bushing). A running clearance of 0.0002-0.0008 in. (0.0051-0.0203 mm) is established during crankcase set or flywheel assembly replacement and engine rebuild.
Page 356: Selection
HOME sm00187 Table 3-28. Pinion Bearing Roller Specifications ROLLER OD COLOR Largest Blue White (gray) Smallest Green Selection Refer to Table 3-29. Select bearings using the identification information given for inner and outer races. 1. Roller OD cannot be measured to required accuracy with micrometer (refer to Pinion Shaft Bearing Selection table) Figure 3-126.
Page 357 HOME The new outer race must be lapped slightly to true and sm03437 align with left case bearing and to meet the following specifications in Table 3-31. See LAPPING PINION SHAFT BEARING OUTER RACE. sm03436 1. 1.70 in. (43.2 mm) 2.
Page 358: Lapping Pinion Shaft Bearing Outer Race
HOME sm00189 sm00190 1. Pinion shaft inner race, 1.145 in. (29.083 mm) - 1. Bearing race remover/installer 1.135 in. (28.829 mm) 2. End cap 2. Flywheel (gear side) 3. Wedge attachment for claw puller Figure 3-131. Inner Race Location Figure 3-130. Removing Pinion Bearing Inner Race NOTES NOTES Have machinist grind inner race to center or middle of...
Page 359: Checking Connecting Rod Side Play
HOME 87) to lapping handle. Assemble guide sleeve to sprocket sm02984 shaft bearing bushing. Sleeves, for use with tapered bearing, are assembled to case with bearings and small spacer collar. Finger-tighten the sleeve parts. Insert lap shaft with arbor assembled through pinion bearing bushing and into guide sleeve.
Page 360 HOME sm02941 1. Spacer, sprocket shaft 2. Retaining ring, oil seal 3. Oil seal 4. Thrust washer 5. Crankcase half 6. Bearing 7. Bearing retaining ring Figure 3-134. Sprocket Shaft Bearing Assembly Figure 3-136. Attach left crankcase half to engine stand.
Page 361 HOME sm00194 sm03929 Figure 3-136. Installing Flywheel Assembly with CRANKSHAFT GUIDE sm00195 Figure 3-137. Pinion Shaft Bearing 1. Shoulder 2. Crankcase bearing remover/installer tool 3. Retaining ring Figure 3-135. Sprocket Shaft Bearing Installation 2010 XB Service: Engine 3-93...
Page 362 HOME sm00176 1. Crankcase fasteners 2. Crankcase fastener behind shifter mechanism Figure 3-138. Crankcase Fasteners Figure 3-138. Assemble crankcase halves together. Apply a thin coat of GREY HIGH-PERFORMANCE sm00196 SEALANT (Part No. 99650-02) to crankcase joint faces. Slide outer race in right crankcase over pinion shaft and bearing assembly.
Page 363 HOME Install sprocket shaft seal. sm00197 Center seal/spacer driver over seal, so that the sleeve (smaller OD) seats between seal wall and garter spring. Sparingly apply graphite lubricant to threads of pilot shaft to verify smooth operation. Slide sleeve over pilot until sleeve contacts the oil seal.
Page 364 NOTES 3-96 2010 XB Service: Engine...
Page 365 TABLE OF CONTENTS SUBJECT..........................PAGE NO. 4.1 FASTENER TORQUE VALUES....................4-1 4.2 SPECIFICATIONS........................4-3 4.3 AIR CLEANER ASSEMBLY.......................4-4 4.4 ELECTRONIC CONTROL MODULE (ECM)................4-7 4.5 THROTTLE POSITION SENSOR (TPS).................4-10 4.6 IGNITION COIL........................4-11 4.7 OXYGEN SENSORS (O2).......................4-12 4.8 ENGINE TEMPERATURE SENSOR (ET)................4-15 4.9 BANK ANGLE SENSOR (BAS)....................4-17 4.10 INTAKE AIR TEMPERATURE SENSOR (IAT)...............4-20 4.11 COOLING FAN........................4-21 4.12 FUEL TANK VENT VALVE.....................4-22...
Page 366 NOTES...
Page 367: Fastener Torque Values
HOME FASTENER TORQUE VALUES FASTENER TORQUE VALUES IN THIS CHAPTER The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE NOTES Air cleaner backplate fasteners 84-120 in-lbs 9.5-13.6 Nm 4.3 AIR CLEANER ASSEMBLY, Installation Bank angle sensor 12-36 in-lbs 1.4-4 Nm...
Page 368 HOME FASTENER TORQUE VALUE NOTES Fuel supply line banjo fitting 84-108 in-lbs 9.5-12.2 Nm 4.14 FUEL PUMP, Installation Fuel tank vent valve fasteners 39-41 in-lbs 4.4-4.6 Nm 4.12 FUEL TANK VENT VALVE, Installation IAC actuator fasteners 25-30 in-lbs 2.8-3.4 Nm 4.15 THROTTLE BODY, Repair Ignition coil mounting screws 120-144 in-lbs...
Page 369: Specifications
HOME SPECIFICATIONS GENERAL Table 4-2. Fuel System Specifications FUEL SYSTEM TYPE Table 4-1. Fuel Tank Specifications Intake (XB9 models) 45 mm downdraft manifold, FUEL TANK CAPACITY GALLONS LITERS ram air Total (including reserve) 4.40 16.7 Intake (XB12 models) 49 mm downdraft manifold, (XB12Ss, XB12XT, XB12X, ram air XB12XP)
Page 370: Air Cleaner Assembly
HOME AIR CLEANER ASSEMBLY REMOVAL sm00896 Remove intake cover. See 2.38 INTAKE COVER. Figure 4-1 Figure 4-2. Remove fuel tank vent tube (4) from fuel tank vent valve (5) and groove on top of air cleaner cover (3). NOTE Figure 4-3 Figure 4-4.
Page 371: Inspection
HOME Insert IAT sensor into grommet on baseplate from under- sm00897 side. NOTES A small amount of soapy water applied to the inside dia- meter of grommet will make breather hose installation easier. In next step, be sure breather hoses do not extend past Intake air temperature sensor tower.
Page 372 HOME sm00898 Actuator, interactive exhaust Filter element Harness, interactive exhaust Air cleaner seal Cable bracket Shoulder screw (4) Interactive exhaust cable Base plate assembly Mounting fasteners, actuator Breather hoses, front and rear 6. Cover, air cleaner Figure 4-5. Air Cleaner Assembly with Interactive Exhaust (XB12 Models, Typical) 4-6 2010 XB Service: Fuel System...
Page 373: Electronic Control Module (Ecm)
HOME ELECTRONIC CONTROL MODULE (ECM) FIREBOLT PART NUMBER TOOL NAME After installing seat, pull upward on seat to be sure it is HD-48650 DIGITAL TECHNICIAN II locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or Removal serious injury.
Page 374 HOME sm00858 Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) Connect battery positive cable (red) first, tightening to 60-70 in-lbs (6.8-7.9 Nm).
Page 375 HOME Figure 4-9. Attach ECM connectors [10] and [11]. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift Connect positive (+) battery cable first. If positive (+) cable causing loss of control, which could result in death or should contact ground with negative (-) cable connected, serious injury.
Page 376: Throttle Position Sensor (Tps)
HOME THROTTLE POSITION SENSOR (TPS) REMOVAL sm00244 Remove air cleaner cover. See 4.3 AIR CLEANER ASSEMBLY. Remove throttle body assembly. See 4.15 THROTTLE BODY. Figure 4-10. Disconnect throttle position sensor con- nector [88]. Figure 4-11. Remove two screws and washers to detach TP sensor.
Page 377: Removal
HOME IGNITION COIL REMOVAL sm00855 To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative battery cable. Remove intake cover assembly. See 2.38 INTAKE COVER. Remove air cleaner cover. See 4.3 AIR CLEANER ASSEMBLY.
Page 378: Removal
HOME OXYGEN SENSORS (O2) GENERAL sm06799 Figure 4-16. The oxygen sensors (O2), located in the front and rear headers, monitors oxygen content in the exhaust gas and converts it to a voltage reading. This voltage reading is used by the ECM to maintain the proper air/fuel ratio during closed loop operation.
Page 379 HOME INSTALLATION NOTES After installing seat, pull upward on seat to be sure it is Do not install sensors that have been dropped or impacted locked in position. While riding, a loose seat can shift by other components. Damage to the sensing element causing loss of control, which could result in death or may have occurred.
Page 380 HOME sm00861b 1. Rear oxygen sensor connector 2. Front oxygen sensor connector, behind engine air scoop, right side, inner Figure 4-17. Oxygen Sensor Connectors [137] Typical 4-14 2010 XB Service: Fuel System...
Page 381: Removal
[90] above rear cylinder head. NOTE Figure 4-20. All Buell engines come equipped with a piece of conduit approximately 3.94 in. (100mm) long to protect the engine temperature sensor lead from chafing on the inside of the rocker box. The conduit will be able to slide as much as 5 Figure 4-19.
Page 382 HOME NOTE sm04650 In next step, make sure wire is in cutout portion (slot) of socket to prevent damage. Secure sensor with ENGINE TEMPERATURE SENSOR SOCKET (Part No. SNAP-ON M3503B). Tighten ET sensor to 120-168 in-lbs (13.6-19 Nm). NOTE Orient the rubber boot so the flat on the boot is towards the left side of the motorcycle.
Page 383: Removal
HOME BANK ANGLE SENSOR (BAS) GENERAL sm00864 The Bank Angle Sensor (BAS) provides input to the ECM on lean angle. If lean angle exceeds the predetermined limit, the BAS will shut off power to the ignition and fuel pump. REMOVAL Firebolt Remove seat.
Page 384: Firebolt
HOME Install bank angle sensor to mounting tab with fasteners sm00865a and new locknuts. Tighten fastener to 12-36 in-lbs (1.4-4 Nm). Figure 4-24. Install bank angle sensor connector [134] (1). Install front fairing. See 2.47 FRONT FAIRING, WIND- SHIELD, AND MIRRORS: FIREBOLT.
Page 385 HOME Ulysses sm00864 Figure 4-25. Install bank angle sensor to mounting tab with fasteners and tighten to 12-36 in-lbs (1.4-4 Nm). Install BAS bracket to seat latch bracket. Tighten fasteners to 72-96 in-lbs (8-10.8 Nm). Install bank angle sensor connector [134]. Connect negative battery cable and tighten fastener to 60-70 in-lbs (6.8-7.9 Nm).
Page 386: Intake Air Temperature Sensor
HOME INTAKE AIR TEMPERATURE SENSOR (IAT) 4.10 GENERAL INSTALLATION The intake air temperature sensor (IAT Sensor), located on Connect IAT sensor connector [89] to wiring harness. the air cleaner cover baseplate, measures the air temperature Install IAT sensor into grommet on air cleaner base from allowing the ECM to calculate the density of the air entering beneath.
Page 387: Installation
HOME COOLING FAN 4.11 Connect negative battery cable, tightening to 60-70 in-lbs GENERAL (6.8-7.9 Nm). A computer-controlled cooling fan assists engine cooling during operation in high temperatures. Fan actuation is controlled by engine temperature and vehicle speed. After installing seat, pull upward on seat to be sure it is REMOVAL locked in position.
Page 388: Installation
HOME FUEL TANK VENT VALVE 4.12 Connect fuel tank vent line to vent valve. GENERAL Install air cleaner cover. See 4.3 AIR CLEANER The fuel tank vent valve opens to allow gas vapor to escape ASSEMBLY. the fuel tank and either vent to the atmosphere or to the char- coal canister on California Models (EVAP-equipped) and closes Install intake cover assembly.
Page 389: Installation
HOME FUEL CAP RETAINING RING 4.13 REMOVAL sm00877 NOTE The fuel tank must be drained to perform this service. Drain fuel tank. See 4.14 FUEL PUMP, Draining Fuel Tank. Remove fuel filler cap. Figure 4-30. Remove fasteners (4) securing fuel cap retaining ring (3) to fuel filler neck (1).
Page 390: Fuel Pump
HOME FUEL PUMP 4.14 DRAINING FUEL TANK REMOVAL NOTES Before vehicle is placed on the lift it will be necessary to remove the chin fairing. See 2.50 CHIN FAIRING. To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is Vehicle should be placed onto the lift with the front tire extremely flammable and highly explosive, which could placed in the wheel vise in order to successfully perform...
Page 391: Installation
HOME 12. Place wrench onto nut and another wrench onto the bolt. INSTALLATION Hold the bolt stationary and turn nut clockwise until fuel pump is pulled free from frame. sm00870a 13. Remove tool from fuel pump. sm00866 Figure 4-34. Fuel Pump Assembly/XB/All Models with Orings 1.
Page 392 HOME sm00223b Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) 12. Connect negative battery cable. Tighten fastener 60-70 in-lbs (6.8-7.9 Nm).
Page 393: Throttle Body
HOME THROTTLE BODY 4.15 10. Remove assembly from motorcycle. GENERAL Figure 4-37. On primary side, loosen but do not The throttle body consists of the following components: remove the two front and rear intake flange fasteners Fuel supply fitting (2). IAC sensor Remove fastener (1) holding manifold to cylinder brace.
Page 394 HOME sm00885 1. Manifold to cylinder brace fastener 2. Intake flange fastener (2) Figure 4-37. Intake Manifold (Primary Side) 4-28 2010 XB Service: Fuel System...
Page 395 HOME sm04397a 88 6 Seal, intake manifold (2) O-ring, fuel injector, inlet Mounting flange, intake (2) Fuel rail Bolt (2) Screw (4) Bolt (2) Gasket, idle air control Nylock nut Fuel pressure sensor Cable wheel O-ring, idle air control Screw (4) Actuator, idle air control Throttle cable retention clip Screw (2)
Page 396: Repair
HOME REPAIR INSTALLATION Throttle Position Sensor NOTES The intake flanges have been extended to improve clamp 4.5 THROTTLE POSITION SENSOR (TPS) for removal, load distribution. installation and calibration information. Intake flanges are interchangeable. Fuel Pressure Sensor Figure 4-38. Install flanges onto throttle body with the Remove and install the fuel pressure sensor while the throttle counterbore (2) facing out.
Page 397: Injector Leak Testing
HOME sm00892 sm00889a Figure 4-39. Extended Intake Flanges sm00885 1. Rear fuel injector 2. Fuel rail fasteners (4) 3. Fuel pressure sensor 4. Fuel rail assembly 5. Front fuel injector Figure 4-41. Fuel Injectors Injector Leak Testing Remove intake cover assembly. See 2.38 INTAKE COVER.
Page 398: Fuel Pressure Sensor
HOME FUEL PRESSURE SENSOR 4.16 Install the battery fuse. REPLACEMENT Turn the ignition switch ON and allow the fuel system to Removal pressurize. Check for leaks. Remove the seat. Install the air cleaner assembly. See 4.3 AIR CLEANER ASSEMBLY. To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected.
Page 399: Fuel Pressure Test
HOME FUEL PRESSURE TEST 4.17 INSPECTION sm00223b PART NUMBER TOOL NAME B-45522 FUEL PRESSURE GAUGE ADAPTER HD-41182 FUEL PRESSURE GAUGE To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury.
Page 400 HOME Note the reading in the display at idle and at 4000 RPM. sm06169 If pressure is between 49-51 PSI (338-352 kPa) at 60 70 ignition ON, and fluctuates between 55-60 PSI (380- 415 kPa) at idle and at 4000 RPM, then system is operating within specifications.
Page 401: Intake Leak Test
HOME INTAKE LEAK TEST 4.18 GENERAL sm02629 Do not allow open flame or sparks near propane. Propane is extremely flammable, which could cause death or ser- ious injury. (00521b) Read and follow warnings and directions on propane bottle. Failure to follow warnings and directions can result in death or serious injury.
Page 402 HOME When test is finished, close valve knob (turn knob fully sm00251 clockwise). Figure 4-48. Checking for Intake Leak 4-36 2010 XB Service: Fuel System...
Page 403: Exhaust System
HOME EXHAUST SYSTEM 4.19 REMOVAL AND DISASSEMBLY Front Muffler Mount Remove muffler. NOTE For details on removal of components on XB12 models with Figure 4-49. Remove front muffler mount fastener interactive exhaust systems, see 6.16 INTERACTIVE (8). EXHAUST SYSTEM, Removal. Remove front muffler strap (5) from front muffler mount Muffler (7).
Page 404: Assembly And Installation
HOME sm00636a Rear muffler strap fastener (2) Front muffler mount fastener Rear muffler strap (2) Front muffler mount bushings Interactive muffler (XB12 models) Interactive exhaust cable Muffler (XB9 models) Rear muffler bracket Front muffler strap Rear muffler bracket fasteners (2) Front muffler strap fastener Symbol for jacking point on muffler (located on 7.
Page 405: Rear Muffler Bracket
Muffler and Straps NOTES To verify sealing integrity of muffler clamps and prevent the possibility of leakage, Buell recommends that muffler clamp assemblies be discarded and replaced each time they are removed. Due to the location of the CKP it will be necessary to align the Torca Clamp to verify proper clearance between the chin fairing and the CKP and Torca clamp.
Page 406: Exhaust System Leak
HOME Exhaust System Leak sm00638a Inspect the muffler to header pipe for leaks. If leaks are present: Remove the muffler Clean all mating surfaces. Replace any damaged components. Install the muffler. Inspect the muffler to header pipe for leaks. If leaks persist: Remove the muffler.
Page 407: Evaporative Emissions Control (Ca Models)
4.20 GENERAL sm00903 Buell motorcycles sold in the state of California are equipped with an evaporative (EVAP) emissions control system. The EVAP system prevents fuel hydrocarbon vapors from escaping into the atmosphere and is designed to meet the California Air Resource Board (CARB) regulations in effect at the time of manufacture.
Page 408: Installation: Lightning/Ulysses
HOME Place rear shock reservoir assembly (3) into position. sm00905 NOTE Figure 4-53. To verify proper reservoir mounting, tempor- arily place upper body work onto tail section and adjust reser- voir placement so adjuster screw (1) aligns with alignment hole (2).
Page 409: Hose Routing
HOME sm00909 sm00910 Figure 4-56. Canister Mounting Bracket 1. Lock tab (6) HOSE ROUTING 2. Air cleaner cover 3. Fuel tank vent hose location Both fuel tank and canister vent hoses are routed through notch 4. Mounting towers for interactive exhaust actuator in fan body.
Page 410 NOTES 4-44 2010 XB Service: Fuel System...
Page 411 TABLE OF CONTENTS SUBJECT..........................PAGE NO. 5.1 FASTENER TORQUE VALUES....................5-1 5.2 SPECIFICATIONS........................5-3 5.3 PRIMARY COVER........................5-4 5.4 CLUTCH RELEASE MECHANISM...................5-8 5.5 CLUTCH..........................5-10 5.6 PRIMARY CHAIN........................5-17 5.7 DRIVE BELT AND IDLER PULLEY..................5-23 5.8 TRANSMISSION........................5-27 5.9 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL............5-28 5.10 TRANSMISSION DISASSEMBLY..................5-31 5.11 TRANSMISSION ASSEMBLY....................5-38 5.12 MAIN DRIVE GEAR AND BEARING..................5-40 5.13 TRANSMISSION RIGHT CASE BEARINGS.................5-47...
Page 412 NOTES...
Page 413: Fastener Torque Values
HOME FASTENER TORQUE VALUES FASTENER TORQUE VALUES IN THIS CHAPTER The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE NOTES Axle, rear (final torque, see ANTI-SEIZE 48-52 ft-lbs 65.1-70.5 Nm 5.7 DRIVE BELT AND IDLER PULLEY, Idler Pulley procedure) Installation/Follow special ANTI-SEIZE procedure.
Page 414 HOME FASTENER TORQUE VALUE NOTES Primary cover fasteners 100-120 in-lbs 11.3-13.6 Nm 5.3 PRIMARY COVER, Installation Primary magnetic drain plug 14-30 ft-lbs 19-40.7 Nm 5.3 PRIMARY COVER, Installation/LOCTITE 565 Shifter bracket fasteners 22-24 ft-lbs 29.8-32.5 Nm 5.3 PRIMARY COVER, Installation/LOCTITE 271 (red) Shift lever pinch screw 48-60 in-lbs...
Page 415: Specifications
HOME SPECIFICATIONS not given under SERVICE WEAR LIMITS, see NEW COMPON- GENERAL ENTS. NOTE Service wear limits are given as a guideline for measuring components that are not new. For measurement specifications Table 5-1. Primary Drive (Engine-to-Transmission) ITEM (XB9SX) (XB12 MODELS) Engine sprocket 34 teeth 38 teeth...
Page 416: Primary Cover
HOME PRIMARY COVER 16. Blow parts dry with low pressure compressed air. REMOVAL Remove seat. sm00351 To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative battery cable from battery. Remove chin fairing.
Page 417: Primary Chain Adjuster Replacement
HOME sm00269 Gasket Screw Oil seal Shifter bushing Rubber shift lever pad Sems screws (13) Primary cover Shifter linkage assembly Adjuster assembly Gasket Bolt Chain adjustment nut Clutch inspection cover Flange bolt O-ring Sems screws (5) Sleeve Drain plug Inspection cover gasket Pedal bearing (2) Rubber washer Cover, inspection...
Page 418: Installation
HOME sm00270 sm00271 Figure 5-5. Primary Cover Tightening Sequence (Typical) Figure 5-5. Tighten fasteners to 100-120 in-lbs (11.3- 13.6 Nm) in sequence shown. Figure 5-3. Install new shifter lever oil seal (19). sm00272 1. Shoe, chain adjuster 2. Chain adjuster screw 1.
Page 419 HOME 12. See Figure 5-8. For Ulysses only, install shifter bracket sm00273 (4) on primary cover (7) by applying LOCTITE 271 (red) to fasteners and tightening to 22-24 ft-lbs (29.8-32.5 Nm). Lightning and Firebolt models do not have a shifter bracket.
Page 420: Clutch Release Mechanism
HOME CLUTCH RELEASE MECHANISM amount of free play at clutch hand lever. See DISASSEMBLY 1.9 CLUTCH/TRANSMISSION/PRIMARY FLUID. NOTE Figure 5-9. Remove three TORX screws with washers For clutch adjustment procedure, see 1.9 CLUTCH/TRANS- (1) and clutch inspection cover (2). MISSION/PRIMARY FLUID.
Page 421: Assembly
HOME ASSEMBLY sm00276 Figure 5-10. Assemble inner and outer ramps. Apply multi-purpose grease to balls (2) and ramps (1, Insert balls in sockets of outer ramp (1). Install inner ramp on hub of outer ramp with tang (3) rotated 180 degrees from hook (6) of outer ramp. Install new retaining ring in groove of outer ramp hub.
Page 422: Clutch
HOME CLUTCH The pressure plate then presses the clutch plates together GENERAL causing the plates to turn as a single unit. The result is that The purpose of the clutch is to smoothly disengage and engage the rotational force of the clutch shell is transmitted through the engine from the rear wheel for starting, stopping and shifting the clutch plates to the clutch hub.
Page 423 HOME sm00278 Spring Diaphragm spring Damper spring Lockplate Retaining ring Damper spring seat Release plate Mainshaft nut Outer ramp Retaining ring Washer Coupling Bearing Clutch hub Ball (3) Adjusting screw Inner thrust washer Inner ramp Pressure plate Needle bearing inner race Retaining ring Friction plate, fiber (7) Needle bearing...
Page 424: Removal
HOME REMOVAL sm00279 PART NUMBER TOOL NAME HD-38515-91 CLUTCH SPRING FORCING SCREW HD-38515-A SPRING COMPRESSING TOOL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Remove negative battery cable from battery. Drain the transmission fluid.
Page 425: Clutch Pack Cleaning And Inspection
HOME CLUTCH PACK CLEANING AND sm00283 INSPECTION Separate the pack in to the following components: Seven fiber plates. Seven steel plates. One narrow fiber plate. One damper spring. One damper spring seat. Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury.
Page 426: Assembly And Installation
HOME If necessary, disassemble adjusting screw assembly. Install a steel plate and then a friction plate on the clutch hub. Install six remaining sets in the same manner, Remove and discard small retaining ring (6). alternating between steel plates and friction plates. Separate the adjusting screw (8) from the bearing (7) and release plate (5).
Page 427 HOME sm00286 sm00280 1. Damper spring 2. Clutch hub 1. Tool handle 3. Steel plate 2. Washer 4. Narrow friction plate 3. Bearing 5. Damper spring seat 4. Bridge 6. Clutch shell 5. Forcing screw Figure 5-19. Clutch Pack Stack-Up (Cut-Away View) 6.
Page 428 HOME Adjust clutch. CLUTCH/TRANSMIS- SION/PRIMARY FLUID, Adjustment. Fill with GENUINE HARLEY-DAVIDSON FORMULA+ After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift TRANSMISSION AND PRIMARY CHAINCASE LUB- RICANT (Part No. 99851-05). See 1.9 CLUTCH/TRANS- causing loss of control, which could result in death or MISSION/PRIMARY FLUID, Transmission...
Page 429: Primary Chain
HOME PRIMARY CHAIN GENERAL sm00289 Since the primary chain runs in lubricant, little service will be required other than checking lubricant level and chain tension. If, through hard usage, the primary chain does become worn and cannot be adjusted to within specifications, it must be replaced.
Page 430: Clutch Shell/Hub Inspection
HOME 10. See Figure 5-28. Inspect clutch shell bearing inner race sm00290 on the back side of the clutch hub for pitting and wear. If the inner race shows any of these signs the complete hub assembly must be replaced. 11.
Page 431: Clutch Shell Bearing Replacement
HOME sm00293 sm00294 1. Removal end of bearing tool 2. Installation end of bearing tool 3. Bearing guide, installer Figure 5-29. Clutch Shell Bearing Remover/Installer Figure 5-28. Clutch Hub Bearing Race sm00295 CLUTCH SHELL BEARING REPLACEMENT PART NUMBER TOOL NAME B-45926 CLUTCH SHELL BEARING REMOVER/INSTALLER...
Page 432: Installation
HOME Figure 5-33. Assemble clutch hub (1) and shell (3) sm00296 by sliding inboard end of clutch hub into shell bearing (2) by hand. No tools are required. Submerge and soak all friction and steel plates in FOR- MULA+ PRIMARY/TRANSMISSION LUBRICANT for at least five minutes and assemble clutch pack in sequence in the clutch hub.
Page 433 HOME Figure 5-35. Install mainshaft washer (2) and nut (1). sm00299 If using original mainshaft nut apply two or three drops of LOCTITE 271 (red) onto threads on end of main- shaft. Place washer (2) on mainshaft with the word "out" facing away from clutch hub.
Page 434 HOME sm00288 1. Adjusting screw assembly 2. Retaining ring 3. Tab recesses Figure 5-37. Clutch Adjusting Screw Assembly and Retaining Ring 5-22 2010 XB Service: Drive/Transmission...
Page 435: Drive Belt And Idler Pulley
HOME DRIVE BELT AND IDLER PULLEY GENERAL NOTE Figure 5-38. Mishandling drive belt will result in premature There is no drive belt adjustment required. The system utilizes failure. For maximum strength, integrity and longevity, avoid a fixed idler pulley that maintains the desired tension throughout over bending, twisting, crimping, pinching, kinking or prying suspension travel and life of the belt.
Page 436: Drive Belt Removal
HOME DRIVE BELT REMOVAL sm00302 Place a scissor jack under jacking point and raise rear wheel off ground. For location of jacking point, see 4.19 EXHAUST SYSTEM. Remove right side rider footpeg support bracket. See 2.34 FOOTPEG, HEEL GUARD AND MOUNT: FIREBOLT AND LIGHTNING MODELS 2.35 HEEL GUARD AND FOOTPEG MOUNTS: ULYSSES...
Page 437: Idler Pulley Removal
HOME 12. Remove scissor jack from motorcycle. Unthread axle approximately 15 rotations to release ten- sion from drive belt. Remove chin fairing fasteners. See 2.50 CHIN FAIRING. sm00303 Remove front sprocket cover. See 2.36 SPROCKET COVER. Figure 5-43. Remove idler pulley bracket nuts and washers (5) from studs (3).
Page 438 HOME Tighten rear axle pinch fastener (2) to 40-45 ft-lbs (54.2- sm00304 61 Nm). 1. Wheel 2. Wheel nut 3. Stud (2) 4. Idler pulley bracket 5. Idler pulley bracket nut and washer (2) 6. Wheel fastener Figure 5-43. Idler Pulley Assembly 5-26 2010 XB Service: Drive/Transmission...
Page 439: Transmission
HOME TRANSMISSION The transmission is foot-operated by the gear shifter lever, GENERAL which transmits the force through a gear shifter shaft. The Figure 5-44. The transmission is a five-speed constant- shifter shaft actuates a pawl and a shifter fork drum. The shifter mesh type housed in an extension of the crankcase.
Page 440: Case Disassembly For Transmission Removal
HOME CASE DISASSEMBLY FOR TRANSMISSION REMOVAL GENERAL sm00307 The rear compartment of the left and right crankcase halves form the transmission case. Servicing of transmission compon- ents requires removing the engine and disassembling (splitting) the crankcase. RIGHT CRANKCASE REMOVAL PART NUMBER TOOL NAME HD-42310/HD-43646 ENGINE SUPPORT STAND...
Page 441 HOME sm00309 sm00310 1. Shifter shaft 2. Return spring 3. Ratchet arms Figure 5-49. Shifter Shaft Assembly 12. See Figure 5-49. Depress ratchet arms (3) in order to clear the shifter drum and remove shifter shaft assembly from left crankcase half. 13.
Page 442 HOME sm00176 1. Crankcase fasteners 2. Crankcase fastener behind shifter mechanism Figure 5-51. Crankcase Fasteners 15. See Figure 5-51. Remove crankcase bolt set (14 fasteners). sm02981 sm00312 Figure 5-52. Separating Crankcase Halves Figure 5-53. Removing Flywheels from Left Crankcase 16. See Figure 5-52.
Page 443: Transmission Disassembly
HOME TRANSMISSION DISASSEMBLY 5.10 Figure 5-55. Remove shifter fork shafts by inserting TRANSMISSION REMOVAL FROM LEFT a small flat punch in the slots and tapping on the end of CRANKCASE each shaft until it falls free. PART NUMBER TOOL NAME NOTE Carefully tap on alternate sides of the shaft using the provided B-43895-1...
Page 444 HOME sm00316 Spring, detent Oil seal Detent spring sleeve assembly Rubber washer Screw, detent assembly Lever, engine Shaft, shifter forks (2) Bolt, engine lever Fork assembly, shifter (2nd-3rd) Bearing, shift lever assembly (2) Fork assembly, shifter (1st) Shift lever Shifter cam assembly Bolt, linkage assembly Fork assembly, shifter (4th-5th) Sleeve, shift/brake lever...
Page 445 HOME sm00317 Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) Figure 5-58. Remove left crankcase half and transmis- sion assembly (4) from engine stand.
Page 446 HOME sm00318 Oil seal Retaining ring Retaining ring Closed end bearing Ball bearing Countershaft 5th gear (integral to shaft) O-ring Countershaft Oil seal Countershaft 1st gear Needle bearing (2) Dog ring Mainshaft 5th gear Countershaft 4th gear Mainshaft 1st gear Countershaft 3rd gear Retaining ring (4) Dog ring...
Page 447: Mainshaft/Countershaft
HOME MAINSHAFT/COUNTERSHAFT MAINSHAFT DISASSEMBLY NOTES PART NUMBER TOOL NAME As the transmission runs, each part develops a certain J-5586-A TRANSMISSION SHAFT RETAINING wear pattern and a kind of "set" with its mating parts. For RING PLIERS this reason, it is important that each component be rein- NOTES stalled in its original location and facing its original direc- tion.
Page 448: Cleaning And Inspection
HOME Figure 5-62. Remove spacer (19) and 2nd gear (18) Cleaning and Inspection from the end of the of the countershaft (2). Remove and discard split bearing (17). Remove spacer (16). Compressed air can pierce the skin and flying debris from NOTE compressed air could cause serious eye injury.
Page 449 HOME sm00321 15 16 Countershaft 5th gear (integral to shaft) Split bearing Countershaft Countershaft 3rd gear Split bearing Thrust washer Countershaft 1st gear Retaining ring Thrust washer Dog ring Retaining ring Spacer Dog ring Split bearing Countershaft 4th gear Countershaft 2nd gear Retaining ring Spacer 10.
Page 450: Transmission Assembly
HOME TRANSMISSION ASSEMBLY 5.11 MAINSHAFT ASSEMBLY NOTES Use correct retaining ring pliers and correct tips. Verify PART NUMBER TOOL NAME that tips are not excessively worn or damaged. J-5586-A RETAINING RING PLIERS During assembly, the split bearings and the internal bores of the gears must be lubricated with Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAIN- CASE LUBRICANT prior to assembly.
Page 451 HOME Expand and install new retaining ring (14). 12. Install new split bearing (17) in 2nd gear position on shaft. 10. Install dog ring (15). Make sure to install with dog ring 13. Install 2nd gear (18) and spacer (19). facing same direction as when it was removed.
Page 452: Main Drive Gear And Bearing
HOME MAIN DRIVE GEAR AND BEARING 5.12 with spacer (8) inner race. Without any support at the inner GENERAL race, the bearing is destroyed. Whenever the main drive gear NOTE is removed, the main drive gear bearing must be replaced. Figure 5-65.
Page 453: Main Drive Gear Bearing
HOME sm00323 sm00325 1. Main drive gear 2. Needle bearing (2) 3. Seal 4. O-ring 5. Retaining ring 1. Cross plate 2. 8 in. bolt Figure 5-66. Main Drive Gear Assembly 3. Main drive gear 4. Washer 5. Bearing 6. Washer sm00324 7.
Page 454: Disassembly
HOME Tighten nut until main drive gear bearing is free. ASSEMBLY Discard main drive gear bearing. PART NUMBER TOOL NAME DISASSEMBLY HD-47855 INNER/OUTER MAIN DRIVE GEAR NEEDLE BEARING INSTALLATION PART NUMBER TOOL NAME TOOL HD-95635-46 CLAW PULLER Use INNER/OUTER MAIN DRIVE GEAR NEEDLE HD-95637-46B WEDGE ATTACHMENT BEARING INSTALLATION TOOL (Part No.
Page 455: Installation
HOME will be at the prescribed depth from the end of the main INSTALLATION drive gear. Refer to Table 5-8. PART NUMBER TOOL NAME Table 5-8. Outer Needle Bearing Depth B-45847 CROSS PLATE HD-35316-12 INSTALLER CUP MODEL DEPTH HD-35316-4A 8 IN. BOLT All Models 0.285 in.
Page 456: Main Drive Gear
HOME destroyed. Whenever the main drive gear is removed, the main sm00330 drive gear bearing must be replaced. Figure 5-74. Lubricate both main drive gear needle bearing assemblies and the mating surface of the main- shaft with HARLEY-DAVIDSON SPECIAL PURPOSE GREASE (Part No.
Page 457 HOME sm00333 sm00334 1. 8 in. bolt 2. Washer 3. Main drive gear 4. Installer cup 5. Bearing 6. Flat washer 7. Nut Figure 5-75. Installing Main Drive Gear (Typical) Main Drive Gear Seal Figure 5-76. Install Pilot (Typical) Figure 5-76.
Page 458 HOME sm00336 sm00338 Figure 5-80. Install Nut (Typical) Figure 5-78. Install Adapter (Typical) sm00339 sm00337 1. Crowfoot wrench 2. 1/2-inch breaker bar 3. Adjustable wrench Figure 5-79. Place Installer over Adapter (Typical) Figure 5-81. Press Seal Into Crankcase 5-46 2010 XB Service: Drive/Transmission...
Page 459: Transmission Right Case Bearings
HOME TRANSMISSION RIGHT CASE BEARINGS 5.13 REMOVAL INSTALLATION PART NUMBER TOOL NAME PART NUMBER TOOL NAME HD-95760-69A BUSHING AND BEARING PULLER A157-8 SNAP-ON BUSHING DRIVER 1/2-INCH ADAPTER HD-95765-69A 1/2 IN. COLLET A157C SNAP-ON BUSHING DRIVER SET Split crankcases in half. See 5.9 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL.
Page 460 HOME sm00322 Retaining ring Right crankcase half Bearing (inner) Ball bearing with spacer Fifth gear mainshaft Retaining ring Bearing (outer) Oil seal O-ring Bearing, (closed end) countershaft Oil seal Bushing, shifter drum Figure 5-82. Transmission Assembly - Right Crankcase Half 5-48 2010 XB Service: Drive/Transmission...
Page 461: Transmission Left Case Bearings
HOME TRANSMISSION LEFT CASE BEARINGS 5.14 diameter of bearing) against outer race. Press bearing REMOVAL into bore until bearing bottoms against shoulder. PART NUMBER TOOL NAME Install new retaining ring with beveled side facing away SNAP-ON PR-36 SNAP RING PLIERS from bearing.
Page 462 HOME sm01370 1. Retaining ring 2. Retaining ring 3. Mainshaft bearing 4. Countershaft bearing Figure 5-85. Ball Bearing Assembly 5-50 2010 XB Service: Drive/Transmission...
Page 463: Transmission Installation
HOME TRANSMISSION INSTALLATION 5.15 INSTALLATION sm00342 PART NUMBER TOOL NAME B-43985-3 INSTALLER B-43985-4 GUIDE B-46285 (4) TRANSMISSION FIXTURE NOTES After re-installing the transmission assembly, verify that all parts have been properly installed. See: 5.12 MAIN DRIVE GEAR AND BEARING 5.11 TRANSMISSION ASSEMBLY 5.14 TRANSMISSION LEFT CASE BEARINGS 5.13 TRANSMISSION RIGHT CASE BEARINGS Make sure crankcase does not begin to tilt when pressed...
Page 464 HOME NOTE sm00358 Figure 5-89. Install shifter fork shafts in the left case half by lightly tapping on the end with a brass hammer until seated in bore. sm00313 1. Installer 2. Press ram 3. Crankcase 4. Countershaft and gears 5.
Page 465 HOME sm03929 sm00343 Figure 5-89. Installing Shift Fork Shafts INSTALLING RIGHT CRANKCASE PART NUMBER TOOL NAME Figure 5-90. Installing Flywheel Assembly with B-45520 GEAR DETENT ASSEMBLY AID CRANKSHAFT GUIDE HD-42326-B CRANKSHAFT GUIDE Figure 5-90. Install the flywheel assembly into the left crankcase half using CRANKSHAFT GUIDE (Part No.
Page 466 HOME sm00312 Figure 5-92. Crankcase Halves sm00176 1. Crankcase fasteners 2. Crankcase fastener behind shifter mechanism Figure 5-93. Crankcase Fasteners 5-54 2010 XB Service: Drive/Transmission...
Page 467: Shifter Shaft
HOME SHIFTER SHAFT 5.16 INSTALLATION sm00346 Figure 5-94. Correctly install shifter return spring onto the reverse side of the shifter shaft assembly before pla- cing shaft in left crankcase half. NOTE Figure 5-95. The shifter shaft return spring can be installed incorrectly and then assembled in the left crankcase half.
Page 468 HOME sm00309 sm00306 Figure 5-98. Hex Fastener Countershaft Retainer Figure 5-97. Installing Shifter Shaft Assembly 5-56 2010 XB Service: Drive/Transmission...
Page 469: Transmission Sprocket
HOME TRANSMISSION SPROCKET 5.17 REMOVAL sm00304 PART NUMBER TOOL NAME B-43982 SPROCKET HOLDING TOOL B-45659 SPROCKET LOCKING TOOL HD-46288 MAINSHAFT LOCKNUT WRENCH HD-94660-37B MAINSHAFT LOCKNUT WRENCH NOTE Use spacer and fastener from B-45659 to install sprocket locking tool. Loosen rear axle pinch fastener. Unthread axle approximately 15 threads to release tension from drive belt.
Page 470 HOME Tighten the transmission sprocket nut an additional 30°- sm00348 40°. NOTE Maximum allowable tightening of sprocket nut is 45° of coun- terclockwise rotation, after initially tightening to 50 ft-lbs. Do not loosen sprocket nut while attempting to align the screw holes.
Page 471 HOME sm00350 sm00302 45° 30° 1. Axle 2. Pinch bolt 1. Transmission sprocket nut 2. Transmission sprocket Figure 5-103. Rear Axle 3. Line scribed on nut and sprocket Figure 5-102. Aligning Transmission Sprocket 2010 XB Service: Drive/Transmission 5-59...
Page 472 NOTES 5-60 2010 XB Service: Drive/Transmission...
Page 473 TABLE OF CONTENTS SUBJECT..........................PAGE NO. 6.1 FASTENER TORQUE VALUES....................6-1 6.2 SPECIFICATIONS........................6-4 6.3 IGNITION/HEADLAMP KEY SWITCH..................6-5 6.4 SPARK PLUG CABLES......................6-13 6.5 CHARGING SYSTEM......................6-15 6.6 BATTERY CABLES.........................6-18 6.7 STARTER..........................6-21 6.8 STARTER SOLENOID......................6-25 6.9 VOLTAGE REGULATOR......................6-28 6.10 ALTERNATOR........................6-30 6.11 HEATED HAND GRIPS: ULYSSES MODELS...............6-32 6.12 HORN............................6-35 6.13 TURN SIGNAL FLASHER.....................6-37 6.14 FRONT TURN SIGNALS.......................6-39...
Page 474 NOTES...
Page 475: Fastener Torque Values
HOME FASTENER TORQUE VALUES FASTENER TORQUE VALUES IN THIS CHAPTER The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE NOTES Actuator fasteners 36-40 in-lbs 4-4.5 Nm 6.16 INTERACTIVE EXHAUST SYSTEM, Installa- tion Battery (+) to starter fastener 60-85 in-lbs 6.8-9.6 Nm 6.6 BATTERY CABLES, Installation...
Page 476 HOME FASTENER TORQUE VALUE NOTES Headlight housing fasteners (Light- 48-72 in-lbs 5.4-8 Nm 6.17 HEADLIGHT, Headlight Bulbs: Lightning and ning/Ulysses) Ulysses heated grip fasteners 14-16 in-lbs 1.6-1.8 Nm 6.11 HEATED HAND GRIPS: ULYSSES MODELS, Heated Hand Grips Horn fastener 72-96 in-lbs 8-10.8 Nm 6.3 IGNITION/HEADLAMP KEY SWITCH, Lightning Horn fastener...
Page 477 HOME FASTENER TORQUE VALUE NOTES Steering head clamp fastener 16-18 ft-lbs 21.7-24.7 Nm 6.26 MAIN WIRE HARNESS, Installation Steering head wiring clamp 16-18 ft-lbs 21.7-24.7 Nm 6.26 MAIN WIRE HARNESS, Installation Steering stem cap 38-42 ft-lbs 51.5-56.9 Nm 6.3 IGNITION/HEADLAMP KEY SWITCH, Firebolt Steering stem pinch fastener 20-22 ft-lbs 27.1-29.8 Nm...
Page 478: Specifications
HOME SPECIFICATIONS GENERAL Table 6-3. Electrical System Specifications ELECTRICAL SYSTEM AMPERES Table 6-1. Battery Specifications Main fuse/battery fuse BATTERY Ignition fuse Size 12 VDC/12 AH/200CCA Light fuse Type Sealed, AGM Accessory fuse Brake/horn/active muffler fuse Table 6-2. Spark Plug Specifications (XB12 models only) SPARK PLUGS ECM fuse...
Page 479: Ignition/Headlamp Key Switch
HOME IGNITION/HEADLAMP KEY SWITCH GENERAL Table 6-10. Indicator Markers ITEM Headlight position marker lamps The automatic-on headlamp feature provides increased (European models only) visibility of the rider to other motorists. Be sure headlamp Headlight high beam Can be is on at all times. Poor visibility of rider to other motorists activated can result in death or serious injury.
Page 480 HOME sm00360 sm00361 1. Upper fork clamp pinch fastener (2) Figure 6-2. Cable Straps On Upper Fork Clamp: Firebolt 2. Stem pinch fastener 3. Stem capnut 4. Upper fork clamp Figure 6-3. Upper Fork Clamp: Firebolt sm00363 1. Headlights (2) 2.
Page 481 HOME Figure 6-2. Attach cable straps to upper fork clamp. sm00362 Install cable strap to the right of ignition switch securing right hand switch and brake line wires to upper fork clamp. Install cable strap to the left of ignition switch securing left hand switch and clutch cable wires to upper fork clamp.
Page 482 HOME sm00473 Turn signal flasher connector [30] Main harness Instrument cluster connector [39] Horn fastener Right handlebar connector [22] Horn mount Left handlebar connector [24] Horn connector [122] Turn signal connectors [31] Horn 6. Ignition switch [33] Figure 6-6. Electrical Connectors Behind Windscreen: Lightning Figure 6-7.
Page 483 HOME sm00476 1. Socket head fastener (1) with spacer behind switch 2. Tamper-resistant Torx fasteners (2) 3. Throttle cables 4. Ignition switch as positioned on vehicle 5. Fork stop pin (retracted) Figure 6-7. Ignition Switch: Lightning (Typical) Disassembly Assembly Figure 6-8.
Page 484 HOME switch body, rotate slot in ignition switch body with screwdriver Connect: until proper installation can be achieved. Instrument cluster connector [39] (2) Mate ignition switch to ignition switch body. Left [24] (4) and right [22] (3) handlebar wiring har- ness connectors Install ignition switch body fasteners (1).
Page 485 HOME While holding the throttle cables to your left (the right side Slide the ignition switch assembly out to your left (the right of the vehicle), pull the ignition switch toward you and roll side of the vehicle). the assembly away from you until the fork stop pin is pointing down.
Page 486 HOME NOTE While holding the throttle cables to your left (the right side In next step, do not force ignition switch (5) into body (2). If of the vehicle), slide the ignition switch assembly in to your ignition switch does not easily slide into ignition switch body, right (the left side of the vehicle).
Page 487: Spark Plug Cables
HOME SPARK PLUG CABLES Figure 6-12. Check spark plug cable resistance with GENERAL an ohmmeter (4). Replace cables not meeting resistance Resistor-type high-tension spark plug cables have a carbon- specifications. impregnated fabric core, instead of solid wire, for radio noise suppression and improved reliability of electronic components.
Page 488 HOME sm00366 Figure 6-13. Boot Gap 6-14 2010 XB Service: Electrical...
Page 489: Charging System
HOME CHARGING SYSTEM GENERAL Alternator The alternator consists of two main components: The charging system consists of the alternator and regulator. Charging system circuits are shown in Figure 6-14 The rotor which mounts to the engine sprocket shaft. Figure 6-15. The stator which bolts to the engine crankcase.
Page 490 HOME sm04729 Battery J-Fuse 30 Amp [5A] [5B] GND 1 [77B] [77A] To fuse and relay block Voltage Regulator Stator [46A] [46B] Battery J-fuse 30A Voltage regulator Battery cable To voltage regulator Stator H-D 1-phase Figure 6-14. Charging System Circuit (Firebolt) 6-16 2010 XB Service: Electrical...
Page 491 HOME sm04730 Battery Fuse/Relay Block Battery Fuse 30 Amp GND 1 [77B] [77A] To fuse and relay block Voltage Regulator Stator [46A] [46B] Battery To voltage regulator Battery cable Voltage regulator 30A battery fuse Stator H-D 1-phase Figure 6-15. Charging System Circuit (Ulysses, Lightning) 2010 XB Service: Electrical 6-17...
Page 492: Battery Cables
HOME BATTERY CABLES Connect cables to frame and starter. REMOVAL Figure 6-19. First, connect positive battery cable to starter using fastener with washer. Tighten fastener to 60-85 in-lbs (6.8-9.6 Nm). To prevent accidental vehicle start-up, which could cause Reinstall protective rubber boot. death or serious injury, disconnect negative (-) battery cable before proceeding.
Page 493 HOME sm00445 sm00393 1. Battery 2. Battery boot 3. Positive battery cable 4. Negative battery cable 5. To frame 6. To starter 7. Red/yellow wires (14 gauge, to be spliced) 8. Battery strap Figure 6-17. Battery: Lightning/Ulysses 1. Battery strap bracket 2.
Page 494 HOME sm00258 1. Positive battery cable 2. Solenoid wire Figure 6-19. Starter Wires (Protective Boot Not Shown) 6-20 2010 XB Service: Electrical...
Page 495: Starter
HOME STARTER GENERAL sm00257 The starter is made up of a field coil assembly, solenoid assembly and drive assembly.The repair instructions contained in this section are divided into three major service areas accordingly. NOTE For troubleshooting and diagnostic information, see the elec- trical diagnostic manual for this motorcycle.
Page 496 HOME Locate the two brushes attached to the field coil winding. Check depth of mica on commutator. If undercut is less Pushing on inboard side of one brush, grasp free end of than 0.008 in. (0.20 mm), use an undercutting machine to brush spring on outboard side with the hooked end of a undercut the mica to 1/32 in.
Page 497 HOME Assembly sm03714 Attach brush holder to field coil. Locate the two brushes attached to the field coil winding. Catch free end of brush spring with the hooked end of a suitable pick. Raise end of brush spring only as far as necessary to install brush into brush holder.
Page 498 HOME Replace snap ring if bent or distorted. the field coil housing flange must engage the slot on solenoid housing flange closest to the short (field wire) Assembly post on the solenoid housing. Install long spring onto drive shaft. Install steel ball in drive 11.
Page 499: Starter Solenoid
HOME STARTER SOLENOID Remove plunger and return spring. SOLENOID ASSEMBLY Assembly Disassembly Apply a light film of LUBRIPLATE 110 to plunger shaft and Remove field coil. See 6.7 STARTER, Field Coil Assembly. install return spring. Install plunger in solenoid. Pull field coil with end cap from solenoid housing. Hold Install new rubber gasket on solenoid cover flange.
Page 500 HOME sm03715 Solenoid Wave washer Hex screw O-ring Solenoid cover Round bushing Rubber gasket Square bushing Plunger Contact plate Return spring Post bolt Rubber boot Paper insulator washer Hex nut Hold-in terminal 9. Jam nut Figure 6-24. Solenoid Assembly Assemble long post (battery): Assembly On inside of solenoid housing, align hole in paper Assemble short post (field coil):...
Page 501 HOME While depressing plunger, alternately tighten jam nuts to Install new rubber gasket on solenoid cover flange. 65-80 in-lbs (7.3-9.0 Nm). Verify that contact plates have Install three hex screws to secure solenoid cover. Altern- not rotated out of alignment with plunger. ately tighten hex screws until snug.
Page 502: Voltage Regulator
HOME VOLTAGE REGULATOR GENERAL sm00391 The voltage regulator is mounted to the front of the crankcase. The voltage regulator is not repairable. Replace the unit if it fails. REMOVAL Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding.
Page 503 HOME sm00392 1. Voltage regulator connector [77] 2. Stator connector [46] 3. Voltage regulator mount bracket 4. Voltage regulator 5. Fastener (3) Figure 6-26. Voltage Regulator 2010 XB Service: Electrical 6-29...
Page 504: Alternator
HOME ALTERNATOR 6.10 REMOVAL AND DISASSEMBLY sm00387 To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative battery cable. Remove primary cover. See 5.3 PRIMARY COVER. Remove clutch assembly, primary chain and engine sprocket/rotor assembly as a unit.
Page 505 HOME thread locking compound. Loss of torque on fasteners could sm00389 result in alternator damage. Position stator (2) on left crankcase half. Secure stator using four new stator fasteners (1). Tighten to 30-40 in- lbs (3.4-4.5 Nm). Install retainer plate with new fasteners and tighten to 56 in-lbs (6.3 Nm).
Page 506: Heated Hand Grips: Ulysses Models
HOME HEATED HAND GRIPS: ULYSSES MODELS 6.11 HEATED HAND GRIPS sm05236 Removal Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect battery negative cable. Remove the windscreen/windshield assembly from the vehicle.
Page 507 HOME sm04632 sm04640 Figure 6-35. Location of Cable Strap Securing the Right Side Hand Grip Wire Below the Instrument Cluster 1. Handlebar wire harness retainer 2. Cable strap for heated hand grip wire Figure 6-36. On the left side, install a cable strap Figure 6-33.
Page 508 HOME NOTE sm04640 After installation is complete, return to the right hand grip wire and rotate the throttle grip to verify the loop has not changed and the moving wire on the heated grip does not make contact with anything when the throttle is rotated. 10.
Page 509: Horn
HOME HORN 6.12 REMOVAL sm00443 Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative battery cable. Access horn: For Firebolt, remove headlight support bracket. See 2.26 HEADLAMP ASSEMBLY AND SUPPORT BRACKET.
Page 510 HOME TROUBLESHOOTING sm00465 If the horn does not sound or fails to function satisfactorily, check for the following conditions: Discharged battery. Loose, frayed, or damaged wiring leading to horn terminal. Verify horn is not making contact with wiring or other components.
Page 511: Turn Signal Flasher
HOME TURN SIGNAL FLASHER 6.13 REMOVAL sm00406 NOTE The turn signal flasher is not repairable. Replace flasher upon failure. Remove front fairing or windshield/windscreen. See 2.47 FRONT FAIRING, WINDSHIELD, AND MIRRORS: FIREBOLT (Firebolt) or 2.48 WINDSHIELD AND WIND- SCREEN: LIGHTNING AND ULYSSES MODELS (Light- ning and Ulysses).
Page 512 HOME sm00459 sm00407 1. Left turn signal 2. Right turn signal Figure 6-46. Turn Signal Controls Figure 6-45. Turn Signal Flasher: Ulysses 6-38 2010 XB Service: Electrical...
Page 513: Front Turn Signals
HOME FRONT TURN SIGNALS 6.14 Check turn signals for proper operation. If operation fails, BULBS reread procedure and verify that all steps were performed. Repair Turn ignition/key switch to ON. Remove screw on back of housing to access turn signal Activate left turn signals using switch on left bulbs.
Page 514: Ulysses
HOME Install turn signal using lockwasher and jam nut. Tighten Attach bullet connectors on turn signal wires as shown in fastener to 25-28 in-lbs (2.8-3.2 Nm). Figure 6-47. Attach bullet connectors on turn signal wires as shown in Figure 6-47. Check turn signals for proper operation.
Page 515 HOME sm03811a 1. Turn signal 2. Jam nut and lockwasher 3. Front module, left and right 4. Windshield 5. Windscreen Figure 6-50. Front Turn Signals: Ulysses 2010 XB Service: Electrical 6-41...
Page 516: Rear Turn Signals
HOME REAR TURN SIGNALS 6.15 BULBS sm00458 Remove screws on back of housing to access turn signal [19A] [19B] bulbs. Rotate bulb 1/4 turn and remove. [19B] [19A] Before replacing, apply a light coat of dielectric grease on the bulb contact terminals. [93A] [93B] Install screw and tighten to 4.4-4.3 in-lbs (0.5-0.6 Nm).
Page 517: Lightning
HOME Check turn signals for proper operation. If operation fails, reread procedure and verify that all steps were performed. Turn ignition/key switch to ON. Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in Activate left turn signals using switch on left death or serious injury.
Page 518: Installation
HOME NOTE In next step, reflector bracket (3) will be removed with turn signal (1). Be sure that all lights and switches operate properly before Remove turn signal from center tail section (5). operating motorcycle. Low visibility of rider can result in death or serious injury.
Page 519: Turn Signal Relocation Bracket: Xb12Xp
HOME Check turn signals for proper operation. If operation fails, Activate right turn signals using switch on left reread procedure and verify that all steps were performed. handlebar. Front and rear right turn signals must flash. Turn ignition key switch to ON. Turn ignition key switch to OFF.
Page 520 HOME sm05991a 1. Relocation bracket, turn signals 2. Tail loop 3. Turn signal, left rear 4. Bracket, license plate illuminationn/center tail section 5. Turn signal, right rear 6. Cover, rear wires 7. Rear reflector bracket 8. License plate lamp Figure 6-56. Rear Turn Signal Relocation Bracket: XB12XP 6-46 2010 XB Service: Electrical...
Page 521: Interactive Exhaust System
HOME INTERACTIVE EXHAUST SYSTEM 6.16 At low RPM with a wide-open throttle, the valve (1) is GENERAL opened to reduce back-pressure so the engine can gain NOTE RPM quickly. The exhaust enters (2) the muffler and flows (3) through the open valve (1) into chamber C (7) and then The interactive exhaust system is standard equipment on the exits (8).
Page 522 HOME sm00375 Interactive exhaust cable Air cleaner cover Harness with connector [161B] Actuator cover (Lightning XB12 models with 3. Interactive exhaust cable bracket translucid cover only) Actuator Screws (Lightning XB12 models with translucid cover only) Figure 6-58. Interactive Control System (XB12 Models) 6-48 2010 XB Service: Electrical...
Page 523: Removal
HOME REMOVAL sm03744 PART NUMBER TOOL NAME HS0020.02A8A HOSE ASSEMBLY Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative battery cable. Remove chin fairing. See 2.50 CHIN FAIRING.
Page 524: Installation
HOME Install cable strap above starter securing actuator cable, sm00376 vent line, main harness and positive battery cable. Install cable strap securing actuator cable, neutral switch and oil pressure wiring. Install front sprocket cover. See 2.36 SPROCKET COVER. 10. Install chin fairing. See 2.50 CHIN FAIRING.
Page 525: Headlight
HOME HEADLIGHT 6.17 GENERAL Dual headlights are equipped with replaceable bulbs. Handle bulb carefully and wear eye protection. Bulb con- High beam headlight is located on the left side of vehicle. tains gas under pressure, which, if not handled carefully, and turns on and off with headlight switch.
Page 526: Headlight Bulbs: Lightning And Ulysses
HOME Check headlight for proper operation. If operation fails, HEADLIGHT BULBS: LIGHTNING AND reread procedure and verify that all steps were performed. ULYSSES Turn ignition key switch to ON. Removal Figure 6-62. Check headlight LOW beam (3) and Remove seat. HIGH beam (2) settings.
Page 527: Installation
HOME sm00446 Headlight Low beam connection [38] (right side) with ground Bulb holder (2) Headlight bulbs 3. High beam connection [38] (left side) with ground Figure 6-64. Headlight Assembly: Lightning/Ulysses (Rear View) NOTE Installation If the rubber boots are not installed correctly the wiring har- NOTE nesses can contact the edge of the forward frame mount.
Page 528 HOME Be sure that all lights and switches operate properly before After installing seat, pull upward on seat to be sure it is operating motorcycle. Low visibility of rider can result in locked in position. While riding, a loose seat can shift death or serious injury.
Page 529 HOME sm00447 Figure 6-65. Headlight Housing 20 Degree Alignment Marks for Rubber Boot Wiring Harness Guides or Spigots 2010 XB Service: Electrical 6-55...
Page 530: Tail Lamp
HOME TAIL LAMP 6.18 Check tail lamp for proper operation. If operation fails, ULYSSES/FIREBOLT/LIGHTNING reread procedure and verify that all steps were performed. Removal Turn ignition key switch to ON. NOTE Check for tail lamp illumination. Tail/stop lamp - Illuminated with LEDs. Replace entire assembly Squeeze front brake hand lever.
Page 531 HOME sm03532a 1. Center tail section 2. Screws (2) 3. Tail lamp 4. License plate lamp (Firebolt) 5. Screws, license plate lamp (2) Figure 6-67. Tail Lamp Assembly: Firebolt/Lightning 2010 XB Service: Electrical 6-57...
Page 532: License Plate Lamp Assembly
HOME LICENSE PLATE LAMP ASSEMBLY 6.19 FIREBOLT Installation Figure 6-68. Install license plate lamp assembly. Removal Insert license plate lamp wiring harness and connec- Remove seat. tions (2) through hole at rear of center tail section (3) and route between the tail section and the tail screen Figure 6-68.
Page 533: Ulysses
HOME Check lamp for proper operation. If operation fails, reread sm00453 procedure and verify that all steps were performed. Turn ignition key switch to ON. Check for license plate lamp illumination. Turn ignition key switch to OFF. After installing seat, pull upward on seat to be sure it is locked in position.
Page 534: Main Fuse And Fuses
HOME MAIN FUSE AND FUSES 6.20 GENERAL sm00373 Buell motorcycles feature two components which protect the electrical system. Fuses Firebolt: See Figure 6-71 Figure 6-72. The covered fuse block is under the seat. Lightning: See Figure 6-73 Figure 6-74. The covered fuse block is under the seat.
Page 535 HOME sm00469 sm00467 1. Fuel pump (10 amp) 2. Auxiliary (10 amp) 3. Main (30 amp) 4. ECM (10 amp) 5. Lamps (15 amp) 6. Key switch (15 amp) 7. Ignition (15 amp) 8. Accessories (10 amp) 9. Brake/horn/interactive exhaust (10 amp) 1.
Page 536 HOME sm00470 sm00467 1. Fuel pump (10amp) 2. Auxiliary (10amp) 3. Battery (30 amp) 4. ECM (10 amp) 5. Lamps (15 amp) 6. Key switch (15 amp) 7. Ignition (15 amp) 8. Accessory (10 amp) 9. Brake/horn/interactive exhaust (10 amp) 10.
Page 537: Neutral Indicator Switch
HOME NEUTRAL INDICATOR SWITCH 6.21 Install sprocket cover. See 2.36 SPROCKET COVER. GENERAL Figure 6-78. The neutral indicator switch (2) is threaded into the transmission portion of the right crankcase half. It is sm00421 immediately forward of the transmission sprocket (1). The sprocket cover must be removed to test the switch.
Page 538: Sidestand Switch (Hdi)
HOME SIDESTAND SWITCH (HDI) 6.22 SIDESTAND SWITCH (HDI) Installation Install fastener through the sidestand switch into the Removal sidestand bracket and tighten to 96-120 in-lbs (10.8-13.6 Disconnect the sidestand switch from the harness between Nm). the left ram air scoop and cylinder head next to the front Route the switch wire harness through the re-closeable V-bracket to frame bolt.
Page 539: Removal
HOME CRANKSHAFT POSITION SENSOR (CKP) 6.23 GENERAL sm02442 The crank position (CKP) sensor is a variable reluctance (VR) sensor that generates an AC signal by sensing the passing of the 30 teeth cast into the engine's left side flywheel. Two con- secutive teeth are missing in the flywheel to establish a refer- ence point.
Page 540 HOME Connect battery positive cable (red) first, tightening to 60-70 in-lbs (6.8-7.9 Nm). See 1.16 BATTERY MAINTEN- ANCE. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift Connect negative battery cable, tightening to 60-70 in-lbs (6.8-7.9 Nm).
Page 541: Removal
HOME VEHICLE SPEED SENSOR (VSS) 6.24 REMOVAL sm00410 Remove sprocket cover. See 2.36 SPROCKET COVER. Disconnect 3-place Deutsch connector [65] under sprocket cover. See 6.29 SPROCKET COVER WIRING. Figure 6-81. Remove fastener (1) to detach vehicle speed sensor (2) from crankcase. INSTALLATION Figure 6-81.
Page 542: Instrument Module
HOME INSTRUMENT MODULE 6.25 Remove the nine fasteners securing the back of the GENERAL module housing to the display and remove back cover. Replace the instrument module if the unit is not working prop- NOTE erly. However, before replacing a component, check that the Do not turn display over.
Page 543: Installation
HOME INSTALLATION sm00466a Figure 6-88 (Firebolt), Figure 6-89 (Lightning) or Figure 6-90 (Ulysses). Place instrument module (2) into position in support (1). Install washers (4) and fasteners (5). Tighten fasteners to 12-36 in-lbs (1.4-4 Nm). Figure 6-85 (Firebolt), Figure 6-86 (Lightning), or Figure 6-87 (Ulysses).
Page 544 HOME sm00415 sm00464 1. Headlight support bracket 1. Fairing support, center 2. Instrument module 2. Instrument module 3. Grommet (3) 3. Grommet (3) 4. Washer (3) 4. Washer (3) 5. Fastener (3) 5. Fastener (3) 6. Instrument module connector [39] 6.
Page 545: Main Wire Harness
HOME MAIN WIRE HARNESS 6.26 NOTES GENERAL Reference the correct figure for the vehicle you are servi- The main wire harness runs from the front of the motorcycle cing: to the tail section. Lightning: See Figure 6-100 Figure 6-93. Always replace plastic tree fasteners when replacing main wire Firebolt: See Figure 6-99.
Page 546 HOME sm00661a Main harness Fuse block and relay center Electronic Control Module Grounds (2) & Bat grd Bank angle sensor (BAS) connector [134] Battery negative cable Main harness grounds (2) (not shown) Battery positive cable Left and right trunk pan fasteners Rear brake light switch connector [121] Right tail section 6.
Page 547 HOME sm06805 1. Left rear turn signal 2. Right rear turn signal 3. License plate lamp 4. Tail lamp connector [93] Figure 6-93. Rear Lamps: Lightning 2010 XB Service: Electrical 6-73...
Page 548 HOME sm00475 Turn signal flasher connector [30] Cable strap Instrument cluster connector [39] Main harness Right handlebar connector [22] Horn fastener Left handlebar connector [24] Horn mount Turn signal connectors [31] Horn connector [122] Ignition switch Horn Figure 6-94. Electrical Connectors Behind Windscreen: Ulysses 6-74 2010 XB Service: Electrical...
Page 549 HOME sm00473 Turn signal flasher connector [30] Main harness Instrument cluster connector [39] Horn fastener Right handlebar connector [22] Horn mount Left handlebar connector [24] Horn connector [122] Turn signal connectors [31] Horn 6. Ignition switch [33] Figure 6-95. Electrical Connectors Behind Windscreen: Lightning 12.
Page 550 HOME Disconnect: 21. Disconnect: Ignition switch [33] (6). Intake air temperature sensor [89]. Turn signal flasher connector [30] (1). Throttle position sensor [88]. Instrument module connector [39] (2). Rear O2 sensor [137]. Left handlebar connector [24] (4) and right handlebar Temperature sensor [90].
Page 551 HOME sm00431 Cable strap Right turn signal connectors Left turn signal connectors Cable strap Data link [91] Right switch housing connector [22] Left switch housing connector [24] Ignition switch connector [33] Cable strap Cable strap 6. Headlight connector [38] Figure 6-96. Fairing Wiring (Viewed From Beneath Fairing): Firebolt 2010 XB Service: Electrical 6-77...
Page 552 HOME sm00475 Turn signal flasher connector [30] Cable strap Instrument cluster connector [39] Main harness Right handlebar connector [22] Horn fastener Left handlebar connector [24] Horn mount Turn signal connectors [31] Horn connector [122] Ignition switch Horn Figure 6-97. Electrical Connectors Behind Windscreen: Ulysses INSTALLATION Feed front and center portion of harness between the trunk pan and tire through opening at rear of frame/fuel tank...
Page 553 HOME NOTE sm00428 Fuel line is installed under engine connector portion of wire harness. Route portion of main wire harness that contains the pos- itive battery cable (3), sprocket cover wiring (4) and transmission vent hose (2) through corner mounting strap and guide (1) at rear of frame.
Page 554 HOME sm00473 Turn signal flasher connector [30] Main harness Instrument cluster connector [39] Horn fastener Right handlebar connector [22] Horn mount Left handlebar connector [24] Horn connector [122] Turn signal connectors [31] Horn 6. Ignition switch [33] Figure 6-99. Electrical Connectors Behind Windscreen: Lightning Install cable strap loosely around main harness (7) and ignition switch (6).
Page 555 HOME 11. Connect: 24. See Figure 6-100 Figure 6-101. Connect: Throttle position sensor [88]. Ground terminals (6) on right side tail section [GRD 1] and [GRD 3]. Intake air temperature sensor [89]. Tail light connectors [93] (13). Rear O2 sensor [137]. Left turn signal connector [19] (11).
Page 556 HOME 37. For Firebolt, install headlight support bracket and install front fairing. See 2.47 FRONT FAIRING, WINDSHIELD, AND MIRRORS: FIREBOLT. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift 38.
Page 557 HOME sm00472 Main harness Ground terminals (low voltage ground wires) Main harness ground (high voltage ground wire) ECM connectors [10] and [11] Battery negative cable Fuse block and relay center Battery positive cable Bank angle sensor (BAS) connector [134] 5. Rear brake light switch connector [121] Figure 6-101.
Page 558 HOME sm04798a Main harness Left rear and right rear tail section fasteners (4) Electronic control module Seat lock cable ECM connectors [10] and [11] Bank angle sensor (BAS) connector [134] Fuse block and relay center Auxiliary power outlet Main harness ground wires [GRD2] Trunk pan Main harness with plastic grommet Left tail section...
Page 559 HOME sm00431 Cable strap Right turn signal connectors Left turn signal connectors Cable strap Data link [91] Right switch housing connector [22] Left switch housing connector [24] Ignition switch connector [33] Cable strap Cable strap 6. Headlight connector [38] Figure 6-103. Fairing Wiring (Viewed From Beneath Fairing): Firebolt 2010 XB Service: Electrical 6-85...
Page 560: Removal
HOME AUXILIARY HARNESS: XB12XP 6.27 XB12XP ULYSSES POLICE MODEL sm06002 AUXILIARY HARNESS Removal NOTE To make sure you properly install the auxiliary harness, make note of wire routing, component bundles and cable strap loca- tions before removing auxiliary harness in order to properly install and maintain component clearances during reassembly.
Page 561 HOME sm06012 1. Between left air scoop and cylinder head 2. Left side of vehicle in front of coil 3. Left side of vehicle to the rear of the coil 4. Near fuel rail and idle air control actuator 5. Rear of fuel tank next to fan Figure 6-105.
Page 562: Installation
HOME sm06009 sm06077 Figure 6-106. Cable Strap: Siren Lead/Auxiliary Harness to Main Harness 17. See Figure 6-106. Remove one cable strap securing siren harness lead to main harness on top of the rear cylinder head close to the fuel rail and the idle air control actuator. 18.
Page 563 HOME Install four cable straps securing auxiliary harness and 16. Install electronic control module. See 4.4 ELECTRONIC main harness to frame. CONTROL MODULE (ECM). Install ignition coil. See 4.6 IGNITION COIL. 17. Install battery. Connect battery positive cable from battery positive NOTES (+) terminal.
Page 564: Interactive Exhaust Harness: Xb12 Models
HOME INTERACTIVE EXHAUST HARNESS: XB12 MODELS 6.28 FIREBOLT sm00433 Removal Remove seat and pillion. Remove intake cover assembly. See 2.38 INTAKE COVER. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Remove negative battery cable from battery.
Page 565: Lightning
HOME NOTE For actuator or actuator cable replacement see 6.16 INTER- ACTIVE EXHAUST SYSTEM. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or sm00911 serious injury.
Page 566: Ulysses
HOME Figure 6-114. Verify that the interactive exhaust cable (3) is routed behind the frame lug (1) before installing air intake cover. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery Figure 6-113. Connect exhaust actuator harness connector [161B] (5).
Page 567 HOME Figure 6-116. Verify that the interactive exhaust cable sm00434 (3) is routed behind the frame lug (1) before installing air intake cover. Figure 6-115. Mate exhaust actuator harness con- nector [165] beneath main harness (6) under seat. Install ground bolt through main battery ground cable. Tighten to 48-72 in-lbs (5.4-8 Nm).
Page 568: Sprocket Cover Wiring
HOME SPROCKET COVER WIRING 6.29 GENERAL REMOVAL Connectors for the neutral switch [131] and the oil pressure Remove sprocket cover. See 2.36 SPROCKET COVER. indicator switch [120] are located under the sprocket cover. Disconnect appropriate connector(s). NOTE sm03744c The actuator cable, neutral switch connector and the oil pres- sure switch wire is located under the sprocket cover.
Page 569: Auxiliary Power Outlets: Ulysses Models
HOME AUXILIARY POWER OUTLETS: ULYSSES MODELS 6.30 GENERAL sm00441 The 12-volt auxiliary power outlet circuit consists of two power outlets for 12-volt electrical accessories. The forward power outlet is located in the dash to the left of the speedometer assembly. The rearward power outlet is located in the tail section under the seat.
Page 570 NOTES 6-96 2010 XB Service: Electrical...
Page 571 TABLE OF CONTENTS SUBJECT..........................PAGE NO. A.1 AMP MULTILOCK CONNECTORS..................A-1 A.2 AUTOFUSE ELECTRICAL CONNECTORS................A-5 A.3 DELPHI CONNECTORS......................A-6 A.4 DEUTSCH ELECTRICAL CONNECTORS................A-8 A.5 DEUTSCH STANDARD TERMINAL REPAIR.................A-12 A.6 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR............A-13 A.7 DEUTSCH MINI TERMINAL REPAIR..................A-15 A.8 PACKARD 150 METRI-PACK CONNECTORS...............A-16 A.9 PACKARD 630 METRI-PACK CONNECTORS...............A-18 A.10 PACKARD METRI-PACK TERMINALS.................A-19 A.11 SEALED SPLICE CONNECTORS..................A-21...
Page 572 NOTES...
Page 573: Amp Multilock Connectors
HOME AMP MULTILOCK CONNECTORS AMP MULTILOCK CONNECTOR REPAIR sm00002 PART NUMBER TOOL NAME HD-41609 AMP MULTILOCK CRIMPER SNAP-ON TT600-3 SNAP-ON PICK General AMP Multilock connectors are found between wire harnesses and component wiring and may be either floating or anchored to the frame with attachment clips.
Page 574 HOME NOTES sm00013 Up and down can be determined by the position of the release button, the button is the top of the connector. On the pin side of the connector, tangs are positioned at the bottom of each cavity, so the slot in the pin terminal (on the side opposite the crimp tails) must face downward.
Page 575 HOME Figure A-4 Figure A-5. Select the pin/socket ter- Figure A-6. Squeeze the handles to cycle the AMP minals from the parts catalog and identify the insulation MULTILOCK CRIMPER (Part No. HD-41609) to the fully crimp tails (1) and the wire crimp tails (2) and the groove open position (1).
Page 576 HOME Inspecting Crimped Terminals sm00007 Figure A-7. Inspect the wire core crimp (2) and insulation crimp (1). Distortion should be minimal. sm00008 1. Insulation crimp 2. Wire core crimp Figure A-7. AMP Multilock Connector: Terminal Crimp 1. Open position 2. Locking bar flange 3.
Page 577: Autofuse Electrical Connectors
HOME AUTOFUSE ELECTRICAL CONNECTORS AUTOFUSE CONNECTOR REPAIR sm02849 PART NUMBER TOOL NAME GA500A SNAP-ON TERMINAL PICK General Autofuse electrical connector terminals are found in ignition switches and some fuse blocks. Disassembly Obtain SNAP-ON TERMINAL PICK (Part No. GA500A). Figure A-8 Figure A-9.
Page 578: Delphi Connectors
HOME DELPHI CONNECTORS DELPHI CONNECTOR REPAIR sm00014 General Delphi connectors are embossed with the brand name, Delphi, on the housing latch. Separating Pin and Socket Housings Figure A-10. Bend back the external latch(es) slightly and separate pin and socket halves of connector. Mating Pin and Socket Housings Push pin and socket halves of connector together until external latch(es) engage.
Page 579 HOME sm00015 1. Remove wire lock 2. Remove terminal lock 3. Pry tang outward Figure A-11. Delphi Connector: Removing Socket Terminals 2010 XB Service: Appendix A Connector Repair A-7...
Page 580: Deutsch Electrical Connectors
HOME DEUTSCH ELECTRICAL CONNECTORS Place large end of slot on attachment clip over T-stud on DEUTSCH CONNECTOR REPAIR frame. Push assembly forward to engage small end of PART NUMBER TOOL NAME slot. HD-41475 DEUTSCH CONNECTOR SERVICE sm00017 HD-41475-100 FLAT BLADE L-HOOK General Deutsch connectors are colored coded for location purposes.
Page 581 HOME NOTE sm00018 Seal plugs (6) are installed through the wire seals of unused chambers. If removed, seal plugs must be replaced to seal the connector. Install internal seal (4) on lip of socket housing, if removed. Insert tapered end of secondary locking wedge (5) into socket housing and press down until it snaps in place.
Page 582 HOME ation of the alignment tabs differ between the black and sm00010 gray connectors, plugs or receptacles must be replaced by those of the same color. When replacing both socket and pin housings, then the black may be substituted for the gray, and vice versa. The socket and pin housings of all other connectors are inter- changeable, that is, the black may be mated with the gray, since the alignment tabs are absent and the orientation...
Page 583 HOME Crimping Terminals sm00020 Identify which of the types of Deutsch terminals are used with the connector and follow the corresponding crimping instruc- tions. Refer to Table A-2. 1. Wire seal 2. Pin housing 3. Pin terminal 4. Locking wedge Figure A-17.
Page 584: Deutsch Standard Terminal Repair
HOME DEUTSCH STANDARD TERMINAL REPAIR straight upward. When positioned, the locking bar fits snugly DEUTSCH STANDARD TERMINAL CRIMPS in the space between the contact band and the core crimp tails. PART NUMBER TOOL NAME Insert stripped wire core between crimp tails until ends HD-39965-A DEUTSCH TERMINAL CRIMP TOOL make contact with locking bar.
Page 585: Deutsch Solid Barrel Mini Terminal Repair
HOME DEUTSCH SOLID BARREL MINI TERMINAL REPAIR DEUTSCH SOLID BARREL TERMINAL sm00023 CRIMPS PART NUMBER TOOL NAME HD-42879 ELECTRICAL CRIMPER TOOL Preparing Wire Leads For Crimping For size 20, 16 and 12 contacts, wire ranges 26-12 AWG. Strip wire lead removing 1/4 in. (6.4 mm) of insulation. Adjusting Crimper Tool Figure A-19.
Page 586 HOME sm00024 1. Contact barrel 2. Indentor cover 3. Indentor point 4. Stripped wire lead Figure A-20. Deutsch Solid Barrel A-14 2010 XB Service: Appendix A Connector Repair...
Page 587: Deutsch Mini Terminal Repair
HOME DEUTSCH MINI TERMINAL REPAIR DEUTSCH MINI TERMINAL CRIMPS Inspecting Crimps Inspect the core and insulation crimps. Distortion should be PART NUMBER TOOL NAME minimal. HD-38125-7 PACKARD TERMINAL CRIMPER Preparing Wire Leads for Crimping sm00022 Strip wire lead removing 5/32 in. (4.0 mm) of insulation. Crimping a Mini Terminal to Wire Lead Figure A-21.
Page 588: Packard 150 Metri-Pack Connectors
HOME PACKARD 150 METRI-PACK CONNECTORS 150 METRI-PACK CONNECTOR REPAIR Inserting Socket Terminal General NOTE For wire location purposes, alpha characters are stamped into Metri-Pack connectors are embossed with the initials (P.E.D.). the socket housings. There are two types of connectors in this series: Figure A-22 for pull-to-seat connector or Figure A-23...
Page 589 HOME sm00027 sm00028 1. Remove wire lock 1. Locate tang in chamber 2. Pivot pin to depress tang 2. Pivot pin to depress tang 3. Pull to remove 3. Push to remove 4. Raise tang to install 4. Raise tang to install Figure A-23.
Page 590: Packard 630 Metri-Pack Connectors
HOME PACKARD 630 METRI-PACK CONNECTORS engages a rib in the chamber wall to lock the terminal in 630 METRI-PACK CONNECTOR REPAIR place. PART NUMBER TOOL NAME Moving to the mating end of the connector, take note of SNAP-ON TT600-3 SNAP-ON PICK the small opening on the chamber wall side of each ter- minal.
Page 591: Packard Metri-Pack Terminals
HOME PACKARD METRI-PACK TERMINALS A.10 METRI-PACK TERMINAL CRIMPS sm00035 PART NUMBER TOOL NAME HD-38125-6 PACKARD TERMINAL CRIMP TOOL HD-38125-7 PACKARD TERMINAL CRIMPER HD-38125-8 PACKARD CRIMPING TOOL Matching Terminal To Crimper Metri-Pack connectors embossed with the initials P.E.D. require Packard crimp tools to crimp terminals to wire leads. Terminals are crimped twice to a wire lead, once over the wire core and a second time over the insulation/seal.
Page 592 HOME Figure A-25. Identify the correct die for the insula- sm00036 tion/seal crimp (2). Position the insulation/seal crimp in the nest. Be sure the insulation/seal crimp tails are facing the forming jaws. Squeeze handle of crimp tool until tightly closed. Tool automatically opens when the crimp is complete.
Page 593: Sealed Splice Connectors
HOME SEALED SPLICE CONNECTORS A.11 Squeeze the handles tightly closed to crimp the lead in SEALED SPLICE CONNECTOR REPAIR the insert (2). The tool automatically opens when the PART NUMBER TOOL NAME crimping is complete. HD-25070 ROBINAIR HEAT GUN Slide the connector to the other half of the metal insert. Insert the stripped wire lead (1) until it stops, and crimp HD-38125-8 PACKARD CRIMPING TOOL...
Page 594 HOME sm00050 sm00051 1. Red connector die 2. Blue connector die 3. Yellow connector die Figure A-26. Packard Crimping Tool (HD-38125-8) 1. Wire lead in metal insert 2. Crimp metal insert 3. Center of crimp 4. Melted sealant Figure A-27. Sealed Splice Connector A-22 2010 XB Service: Appendix A Connector Repair...
Page 595 TABLE OF CONTENTS SUBJECT..........................PAGE NO. B.1 CONNECTORS........................B-1 B.2 WIRING DIAGRAMS.........................B-4...
Page 596 NOTES...
Page 597 Place and Color Refer to Table B-1. The place (number of wire cavities of a connector housing) and color of the connector can also aid identification. Table B-1. 2010 Buell XB Connector Locations DESCRIPTION TYPE TERMINAL PROBE LOCATION COLOR J-Fuse...
Page 598 HOME Table B-1. 2010 Buell XB Connector Locations DESCRIPTION TYPE TERMINAL PROBE LOCATION COLOR [45] License plate lamp 2-place JST Under rear wire cover (Ulysses, Lightning) Under tail section (Firebolt) [46] Stator 2-place Dekko Below left ram air scoop [61]...
Page 599 HOME Table B-1. 2010 Buell XB Connector Locations DESCRIPTION TYPE TERMINAL PROBE LOCATION COLOR [165] Exhaust valve actuator subhar- 4-place Deutsch Black Under seat ness to main harness [178] 2-place Deutsch Black Under air cleaner cover [180] Rear auxiliary power outlet...
Page 600 HOME WIRING DIAGRAMS WIRING DIAGRAM INFORMATION ed01711 Wire Color Codes Wire traces on wiring diagrams are labeled with alpha codes. Refer to Table B-2. For Solid Color Wires: See Figure B-1. The alpha code identifies wire color. For Striped Wires: The code is written with a slash (/) between the solid color code and the stripe code.
Page 601 HOME ed03137 ed03134 19 13 11 20 18 12 10 8 1. Fuse block 1. Ignition relay 2. Fuel pump fuse 2. Start relay 3. Brake/horn/EVA 3. Key switch relay 4. Cooling fan 4. Auxiliary relay 5. Ignition 5. Relay block 6.
Page 602 HOME ed03133 Table B-2. Wire Color Codes ALPHA CODE WIRE COLOR Blue Black 19 13 11 Brown Green Gray Light Green Orange Pink 20 18 12 10 8 Violet White Yellow 1. Ignition relay 2. Start relay 3. Fuse block 4.
Page 603 HOME 2010 XB WIRING DIAGRAMS Wiring Diagram List DIAGRAM LOCATION Battery Power: 2010 XB Models (Ulysses, Lightning) Figure B-6 Battery Power: 2010 XB Models (Firebolt) Figure B-7 Ignition/Accessory Power: 2010 XB Models (Ulysses, Lightning) Figure B-8 Ignition/Accessory Power: 2010 XB Models (Firebolt) Figure B-9 Chassis Grounds: 2010 XB Models (Ulysses, Lightning) Figure B-10...
Page 604 HOME em00366 Battery Cable Starter Solenoid [128A] Starter Motor Battery Auxiliary Battery Fuel Ignition Cooling Pump Switch Auxiliary Relay Fuse Block [77B] [86A] [10B] [97B] Key Switch [77A] [86B] [10A] [97A] Relay 30 3 Voltage Fuel Cooling Regulator Pump Ignition Relay GY/O Relay...
Page 605 HOME em00429 Battery Cable Starter Solenoid [128A] Starter Motor Battery J-fuse Auxiliary Fuel Ignition Cooling Pump Switch Auxiliary Relay Fuse Block [77B] [86A] [10B] [97B] Key Switch [77A] [86B] [10A] [97A] Relay 30 3 Voltage Fuel Cooling Regulator Pump Ignition Relay GY/O Relay...
Page 606 HOME em00367 Ignition Switch Off Lock Off Lock Park Park [33A] [33B] Battery Power In Wiring Diagrams R/BK Switch License Relay Plate Tail Fuse Acces- Lights Brake/ Lamp Light Block sory Horn/ Start Relay [93A] [45A] [45B] [93B] Relay Block Instrument R/BK 12 12...
Page 607 HOME em00430 Ignition Switch Off Lock Off Lock Park Park [33A] [33B] Battery Power In Wiring Diagrams R/BK License Switch Plate Tail Relay Lamp Light Fuse Acces- Lights Brake/ R/BK Block sory Horn/ R/BK Start [45A] [93A] Relay [45B] [93B] [7B] [7A] Relay...
Page 608 HOME em00742 Battery Tender [55] Battery Relay Right Rear Block Turn Signal [10A] Ignition [18A] [18B] Relay [10B] Tail Light Switch Marker [93A] [93B] Relay Lamp High License Beam Beam Plate Lamp Headlamp Headlamp [45A] [45B] Fuel Pump [86A] [86B] Left Rear Turn Signal [19A]...
Page 609 HOME Left Rear Right Rear em00741 Turn Signal Turn Signal Battery License Tail Tender Plate Lamp Light [55] [19A] [45A] [93A] [18A] [10A] [19B] [45B] [93B] [18B] [10B] Relay Block Ignition Relay Low Beam Headlamp Switch Left Marker Relay Lamp Right Marker Lamp High Beam...
Page 611 Exhaust Fuel Pump [11B] [11A] et00291 Valve Voltage Neutral Pressure Foot Brake Starter TN/LGN Clutch Switch Actuator Cooling (Japan Only) Regulator [11A] Sensor Switch Switch Solenoid TN/Y Sub-Harness Neutral Switch (GY) GND 5 TN/V Active Muffler Feedback (Japan Only) [178A] GN/BE Fuel Pressure Sensor PK/Y...
Page 612 Figure B-12. Figure B-12. Main Harness: 2010 XB Models (Ulysses and Lightning) Main Harness: 2010 XB Models (Ulysses and Lightning)
Page 613 Key Switch Ignition Horn Headlight Right Turn Battery Fuel Pump 10A Fuse Assembly Left Turn Signal et00292 [38B] Tender Signal O/GY Auxiliary 10A [55] Brake/Horn/EVA 10A Relay [122A] R/BK Center ECM 10A R/BK [122B] Cooling Fan 10A [31B] [31B] Y/BN [62B] Lights 15A Igniton 15A...
Page 614 Figure B-13. Figure B-13. Main Harness: 2010 XB Models (Firebolt) Main Harness: 2010 XB Models (Firebolt)
Page 615 Ignition [83B] [83A] ET Sensor et00293 (Japan Only) Fuel [88A] [88B] Switch [33A] [33B] [90B] [90A] Pressure Ignition Y/BE [227B] Sensor A B C Coil [178A] BK/W PK/Y PK/Y [87B] BE/O 1 2 3 4 R/GY R/BK R/BK O2 Sensor Rear [137B] [137A] V/GN...
Page 616 Figure B-14. Figure B-14. Engine Management Circuit: 2010 XB Models (Ulysses and Engine Management Circuit: 2010 XB Models (Ulysses and Lightning) Lightning)
Page 617 et00294 To Main Harness Front Turn Signals LH Turn Signal To Main Harness LH Turn Signals [38B] [93A] 1 3 2 Headlight Sub-Harness [19A] [31A] [31B] LIC Plate Lamp [38LA] Main Harness To Main RH Turn Signals Harness H7-55W [45A] Hi And Lo Beams RH Turn Signal...
Page 618 Figure B-15. Figure B-15. Component Wiring Diagrams: 2010 XB Models Component Wiring Diagrams: 2010 XB Models...
Page 619 HOME em00775 On/Off Switch [J9A] [J5B] [J4B] [J9B] [J6B] [J7B] Lighting/Siren [J2A] [J2B] Control Module Switch Power Signal Control Indicator Switch + Indicator Switch - Front Channel 2 + BE/W Front Channel 2 - BE/BK Front Channel 1 + GN/W Front Channel 1 - GN/BK Siren...
Page 620 NOTES B-24 2010 XB Service: Appendix B Wiring...
Page 621 TABLE OF CONTENTS SUBJECT..........................PAGE NO. C.1 LENGTH CONVERSION......................C-1 C.2 FLUID CONVERSION......................C-2 C.3 TORQUE CONVERSION......................C-3...
Page 622 NOTES...
Page 623 HOME LENGTH CONVERSION CONVERSION TABLE Table C-1. Metric Conversions MILLIMETERS to INCHES INCHES to MILLIMETERS (MM x 0.03937 = IN) (IN x 25.40 = MM) .0039 .9842 2.283 3.582 .001 .025 15.240 1-15/16 49.21 3-5/16 84.14 .0078 1.024 2.323 3.622 .002 .051 15.875...
Page 624: Fluid Conversion
HOME FLUID CONVERSION UNITED STATES SYSTEM BRITISH IMPERIAL SYSTEM Unless otherwise specified, all fluid volume measurements in Fluid volume measurements in this Service Manual do not this Service Manual are expressed in United States (U.S.) include the British Imperial (Imp.) system equivalents. The fol- units-of-measure.
Page 625: Torque Conversion
HOME TORQUE CONVERSION UNITED STATES SYSTEM METRIC SYSTEM The U.S. units of torque, foot pounds and inch pounds, are All metric torque specifications are written in Newton-meters used in this service manual. To convert units, use the following (Nm). To convert metric to United States units and United equations: States to metric, use the following equations: foot pounds (ft-lbs) X 12.00000 = inch pounds (in-lbs).
Page 626 NOTES C-4 2010 XB Service: Appendix C Conversions...
Page 627 TABLE OF CONTENTS SUBJECT..........................PAGE NO. D.1 APPENDIX D: HOSE AND WIRE ROUTING................D-1...
Page 628 NOTES...
Page 629: Appendix D Hose And Wire Routing
HOME APPENDIX D: HOSE AND WIRE ROUTING FIREBOLT 2010 XB Service: Appendix D Hose and Wire Routing D-1...
Page 630 HOME sm04328 Figure D-1. Front and Rear Brake Systems, Right Side View D-2 2010 XB Service: Appendix D Hose and Wire Routing...
Page 631 HOME sm04332 Figure D-2. Rear Brake Systems, Top View 2010 XB Service: Appendix D Hose and Wire Routing D-3...
Page 632 HOME sm04334 Figure D-3. Rear Brake Systems, Left Side View D-4 2010 XB Service: Appendix D Hose and Wire Routing...
Page 633 HOME sm04337 1. Carbon canister Figure D-4. Evaporative Emissions Control, California Models, Top View 2010 XB Service: Appendix D Hose and Wire Routing D-5...
Page 634 HOME sm04340 1. To induction module 2. From induction module (California) 3. From fuel tank (California) 4. From fuel tank to atmosphere (49 state) Figure D-5. Evaporative Emissions Control, California and 49 State Models, Left Side View D-6 2010 XB Service: Appendix D Hose and Wire Routing...
Page 635 HOME sm04344 1. Active intake solenoid (Japan only) 2. Ignition coil 3. Fuel pump 4. Crank position sensor (CKP) 5. To ECM Figure D-6. Wiring Harness, Left Side View 2010 XB Service: Appendix D Hose and Wire Routing D-7...
Page 636 HOME sm04346 1. Fuel injector (2) 2. Idle air control (IAC) 3. Throttle position sensor (TPS) 4. Intake air temperature sensor (IAT) 5. Oxygen sensor (O2) 6. Engine temperature sensor Figure D-7. Wiring Harness, Top View D-8 2010 XB Service: Appendix D Hose and Wire Routing...
Page 637 HOME sm04349 1. Vehicle speed sensor (VSS) 2. Cable, starter to battery positive 3. Solenoid 4. Voltage regulator 5. Oil pressure switch 6. Neutral switch 7. Relay terminal Figure D-8. Wiring Harness, Right Side View 2010 XB Service: Appendix D Hose and Wire Routing D-9...
Page 638 HOME sm04322 1. Feed oil line 2. Return oil line 3. Vent line 4. Oil cooler return line 5. Oil cooler feed line Figure D-9. Oil Lines, Right Side View D-10 2010 XB Service: Appendix D Hose and Wire Routing...
Page 639 HOME sm04367 1. Exhaust valve actuator 2. Muffler valve Figure D-10. Clutch Cable and Exhaust Valve Actuator, Right Side View 2010 XB Service: Appendix D Hose and Wire Routing D-11...
Page 640 HOME sm04371 1. Muffler valve 2. Exhaust valve actuator 3. Cable, seat lock Figure D-11. Clutch, Throttle, Seat Release Cable and Exhaust Valve Actuator, Left Side View D-12 2010 XB Service: Appendix D Hose and Wire Routing...
Page 641 HOME sm04374 1. Cable, seat lock 2. Exhaust valve actuator (mounted to top of functional air cleaner cover) Figure D-12. Clutch, Throttle, Seat Release Cable and Exhaust Valve Actuator (XB12 Models), Top View 2010 XB Service: Appendix D Hose and Wire Routing D-13...
Page 642: Lightning
HOME LIGHTNING sm04329 Figure D-13. Front and Rear Brake Systems, Right Side View D-14 2010 XB Service: Appendix D Hose and Wire Routing...
Page 643 HOME sm04331 Figure D-14. Rear Brake Systems, Top View 2010 XB Service: Appendix D Hose and Wire Routing D-15...
Page 644 HOME sm04335 Figure D-15. Rear Brake Systems, Left Side View D-16 2010 XB Service: Appendix D Hose and Wire Routing...
Page 645 HOME sm04338 1. Carbon canister Figure D-16. Evaporative Emissions Control, California Models, Top View 2010 XB Service: Appendix D Hose and Wire Routing D-17...
Page 646 HOME sm04342 1. To induction module 2. From induction module (California) 3. From fuel tank (California) 4. From fuel tank to atmosphere (49 state) Figure D-17. Evaporative Emissions Control, California and 49 State Models, Left Side View D-18 2010 XB Service: Appendix D Hose and Wire Routing...
Page 647 HOME sm04327 1. Active Intake Solenoid (Japan only) 2. Ignition coil 3. Fuel pump 4. Crank position sensor (CKP) Figure D-18. Wiring Harness, Left Side View 2010 XB Service: Appendix D Hose and Wire Routing D-19...
Page 648 HOME sm04347 1. Fuel injector (2) 2. Idle air control (IAC) 3. Throttle position sensor (TPS) 4. Intake air temperature sensor (IAT) 5. Oxygen sensor (02) Figure D-19. Wiring Harness, Top View D-20 2010 XB Service: Appendix D Hose and Wire Routing...
Page 649 HOME sm04351 1. Vehicle speed sensor (VSS) 2. Cable, starter to battery positive 3. Solenoid 4. Voltage regulator 5. Oil pressure switch 6. Neutral switch 7. Relay terminal Figure D-20. Wiring Harness, Right Side View 2010 XB Service: Appendix D Hose and Wire Routing D-21...
Page 650 HOME sm04325 1. Feed oil line 2. Return oil line 3. Vent line 4. Oil cooler return line 5. Oil cooler feed line Figure D-21. Oil Lines, Right Side View D-22 2010 XB Service: Appendix D Hose and Wire Routing...
Page 651 HOME sm04369 1. Exhaust valve actuator 2. Muffler valve Figure D-22. Clutch Cable and Exhaust Valve Actuator (XB12 Models), Right Side View 2010 XB Service: Appendix D Hose and Wire Routing D-23...
Page 652 HOME sm04372 1. Muffler valve 2. Exhaust valve actuator 3. Cable, seat lock Figure D-23. Clutch, Throttle, Seat Release Cable and Exhaust Valve Actuator (XB12 Models), Left Side View D-24 2010 XB Service: Appendix D Hose and Wire Routing...
Page 653 HOME sm04375 1. Cable, seat lock 2. Exhaust valve actuator (mounted to top of functional air cleaner cover) Figure D-24. Clutch, Throttle, Seat Release Cable and Exhaust Valve Actuator (XB12 Models), Top View 2010 XB Service: Appendix D Hose and Wire Routing D-25...
Page 654: Ulysses
HOME ULYSSES sm04330 Figure D-25. Front and Rear Brake Systems, Right Side View D-26 2010 XB Service: Appendix D Hose and Wire Routing...
Page 655 HOME sm04333 Figure D-26. Rear Brake Systems, Top View 2010 XB Service: Appendix D Hose and Wire Routing D-27...
Page 656 HOME sm04336 Figure D-27. Rear Brake Systems, Left Side View D-28 2010 XB Service: Appendix D Hose and Wire Routing...
Page 657 HOME sm04339 Figure D-28. Evaporative Emissions Control, California Models, Top View 2010 XB Service: Appendix D Hose and Wire Routing D-29...
Page 658 HOME sm04361 1. To induction module 2. From induction module (California) 3. From fuel tank (California) 4. From fuel tank to atmosphere (49 state) Figure D-29. Evaporative Emissions Control, California and 49 State Models, Left Side View D-30 2010 XB Service: Appendix D Hose and Wire Routing...
Page 659 HOME sm04326 1. Active intake solenoid (Japan only) 2. Ignition coil 3. Fuel pump 4. Crank position sensor (CKP) Figure D-30. Wiring Harness, Left Side View 2010 XB Service: Appendix D Hose and Wire Routing D-31...
Page 660 HOME sm04348 1. Fuel injector (2) 2. Idle air control (IAC) 3. Throttle position sensor (TPS) 4. Intake air temperature sensor (IAT) 5. Oxygen sensor (O2) Figure D-31. Wiring Harness, Top View D-32 2010 XB Service: Appendix D Hose and Wire Routing...
Page 661 HOME sm04353 1. Vehicle speed sensor (VSS) 2. Cable, starter to battery positive 3. Solenoid 4. Oil pressure switch 5. Neutral switch 6. Relay terminal Figure D-32. Wiring Harness, Right Side View 2010 XB Service: Appendix D Hose and Wire Routing D-33...
Page 662 HOME sm04444 1. Vent line 2. Feed oil line 3. Return oil line 4. Feed oil line from the oil pump to the oil cooler 5. Return oil line from the oil cooler to the oil filter housing Figure D-33. Oil Lines, Right Side View D-34 2010 XB Service: Appendix D Hose and Wire Routing...
Page 663 HOME sm04370 1. Exhaust valve actuator 2. Muffler valve Figure D-34. Clutch Cable and Exhaust Valve Actuator, Right Side View 2010 XB Service: Appendix D Hose and Wire Routing D-35...
Page 664 HOME sm04373 1. Muffler valve 2. Exhaust valve actuator 3. Cable, seat lock Figure D-35. Clutch, Throttle, Seat Release Cable and Exhaust Valve Actuator, Left Side View D-36 2010 XB Service: Appendix D Hose and Wire Routing...
Page 665 HOME sm04376 1. Cable, seat lock 2. Exhaust valve actuator (mounted to top of functional air cleaner cover) Figure D-36. Clutch, Throttle, Seat Release Cable and Exhaust Valve Actuator (XB12 Models), Top View 2010 XB Service: Appendix D Hose and Wire Routing D-37...
Page 666 NOTES D-38 2010 XB Service: Appendix D Hose and Wire Routing...
Page 667 TABLE OF CONTENTS SUBJECT..........................PAGE NO. E.1 ACTIVE INTAKE SYSTEM (JAPANESE MODELS ONLY)............E-1...
Page 668 NOTES...
Page 669: Appendix E Active Intake (Japanese Models)
HOME ACTIVE INTAKE SYSTEM (JAPANESE MODELS ONLY) While holding the throttle wide open, activate the active GENERAL intake tab on Digital Technician. PART NUMBER TOOL NAME Verify that the TPS setting is between 10.4-10.9 degrees. HD-41404 TEST CONNECTOR KIT If settings are not correct proceed to cable adjustment Active Intake System procedure.
Page 670 HOME sm03607 1. Solenoid shaft 2. Cable adjusting and jam nuts 3. Solenoid bracket 4. Cable housing Figure E-1. Checking for Freeplay in the Solenoid Shaft in the Fully Retracted Position Figure E-2. Inspect for proper extension freeplay in NOTE solenoid shaft: You should be able to move the solenoid shaft slightly outward until the shaft is fully extended.
Page 671: Throttle Stop Screw
HOME sm03608 1. Solenoid shaft 2. Cable adjusting and jam nuts 3. Solenoid bracket 4. Cable housing Figure E-2. Checking for Freeplay in the Solenoid Shaft in the Fully Extended Position Adjust stop screw, while reading the TPS on Digital Throttle Stop Screw Technician, until setting is between the range of 10.4 to Remove cosmetic intake cover assembly and functional...
Page 672: Removal
HOME sm03609 1. Cable stop screw 2. Active cable wheel Figure E-3. Active Intake Cable Stop Screw REMOVAL Unthread cable connector and disconnect cable from solenoid (8). NOTE Loosen jam nut (5) and disconnect active cable (2) from If solenoid bracket needs to be replaced, remove the baseplate cable bracket (4).
Page 673: Installation
HOME Remove the two fasteners at the front on the solenoid the throttle body. If the cable comes out the cable will not work bracket (9) and slide solenoid (8) out of bracket. properly and will not be able to be adjusted. NOTE NOTES When installing baseplate be sure to feed the electrical...
Page 674 NOTES E-6 2010 XB Service: Appendix E Active Intake (Japanese Models)
Page 675: Appendix F Glossary
TABLE OF CONTENTS SUBJECT..........................PAGE NO. F.1 GLOSSARY..........................F-1...
Page 676 NOTES...
Page 677: Glossary
HOME GLOSSARY ACRONYMS AND ABBREVIATIONS Table F-1. Acronyms and Abbreviations ACRONYM OR ABBREVIATION DESCRIPTION Amperes Anti-lock braking system Ampere-hour Alternating current Accessory position on ignition switch Automatic compression release Active Intake Solenoid Absorbed glass mat (battery) American wire gauge Battery voltage Bank angle sensor BTDC Before top dead center...
Page 678 HOME Table F-1. Acronyms and Abbreviations ACRONYM OR ABBREVIATION DESCRIPTION Foot ft-lbs Foot pounds fl oz Fluid ounce Gram Gallon GAWR Gross axle weight rating Global positioning system Ground (electrical) GVWR Gross vehicle weight rating Hydraulic control unit Harley-Davidson International H-DSSS Harley-Davidson smart security system HFSM...
Page 679 HOME Table F-1. Acronyms and Abbreviations ACRONYM OR ABBREVIATION DESCRIPTION Miles per hour millisecond Newton-meter NiMH Nickel metal hydride Not applicable Oxygen Outside diameter Original equipment manufacturer Ounce P&A Parts and Accessories Part No. Part number Personal identification number Pounds per square inch PWM signal Pulse width modulated signal Quart...
Page 680 NOTES F-4 2010 XB Service: Appendix F Glossary...
Page 681 Tools Used in This Manual PART NUMBER TOOL NAME NOTES 217801 NICE BEARING 2.6 REAR WHEEL, Wheel Bearings: Three Bearing Wheels 94654-98 SUPERSMART BATTERY TENDER 1.16 BATTERY MAINTENANCE, Storage A157-8 SNAP-ON BUSHING DRIVER 1/2-INCH 5.13 TRANSMISSION RIGHT CASE BEARINGS, Install- ADAPTER ation A157C...
Page 682: Ii Tools
TRANSMISSION FIXTURE 5.15 TRANSMISSION INSTALLATION, Installation B-48867-47MM FORK SEAL DRIVER AND DUST BOOT 2.16 FRONT FORKS, Assembly INSTALLER B-50019 BUELL WHEEL BEARING 2.6 REAR WHEEL, Wheel Bearings: Three Bearing INSTALLER/REMOVER Wheels B50019-2 SPACER 2.6 REAR WHEEL, Wheel Bearings: Three Bearing...
Page 683 Tools Used in This Manual PART NUMBER TOOL NAME NOTES HD-21000 TIRE SPREADER 2.7 TIRES, Cleaning and Inspection HD-25070 ROBINAIR HEAT GUN A.11 SEALED SPLICE CONNECTORS, Sealed Splice Connector Repair HD-33223-1 CYLINDER COMPRESSION GAUGE 3.3 ENGINE, Compression Test HD-33446-86 XL EVOLUTION TORQUE PLATE BOLTS 3.8 CYLINDER AND PISTON, Cleaning and Inspection HD-33446B CYLINDER TORQUEPLATES...
Page 684 Tools Used in This Manual PART NUMBER TOOL NAME NOTES HD-39302 STEERING HEAD BEARING RACE 2.18 STEERING HEAD BEARINGS, Installation INSTALLER HD-39786 CYLINDER HEAD HOLDING FIXTURE 3.7 CYLINDER HEAD, Procedure For Using The Neway Valve Seat Cutter HD-39965-A DEUTSCH TERMINAL CRIMP TOOL A.5 DEUTSCH STANDARD TERMINAL REPAIR, Deutsch Standard Terminal Crimps HD-39969...
Page 685 Tools Used in This Manual PART NUMBER TOOL NAME NOTES HD-45966 FRONT FORK COMPRESSOR 2.16 FRONT FORKS, Disassembly HD-46283 FOR XB12 SPROCKET LOCKING LINK 5.6 PRIMARY CHAIN, Removal MODELS HD-46283 FOR XB12 SPROCKET LOCKING LINK 5.6 PRIMARY CHAIN, Installation MODELS HD-46288 MAINSHAFT LOCKNUT WRENCH 5.17 TRANSMISSION SPROCKET, Removal...
Page 686 Tools Used in This Manual PART NUMBER TOOL NAME NOTES J-23444-A EXTREME PRESSURE LUBRICANT 2.6 REAR WHEEL, Wheel Bearings: Three Bearing Wheels J-5586-A TRANSMISSION SHAFT RETAINING RING 3.8 CYLINDER AND PISTON, Fitting Piston Rings PLIERS J-5586-A TRANSMISSION SHAFT RETAINING RING 5.10 TRANSMISSION DISASSEMBLY, Mainshaft Disas- PLIERS sembly...
Page 687 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Active cable jam nut 48-60 in-lbs 5.4-6.8 Nm E.1 ACTIVE INTAKE SYSTEM (JAPANESE MODELS ONLY), Installation Active intake cable connector 20-24 in lbs 2.3-2.7 Nm E.1 ACTIVE INTAKE SYSTEM (JAPANESE...
Page 688: Viii Torque Values
2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Battery terminal fastener 60-70 in-lbs 6.8-7.9 Nm 1.16 BATTERY MAINTENANCE, Battery Installa- tion and Connection Battery terminal fastener 60-70 in-lbs 6.8-7.9 Nm 1.16 BATTERY MAINTENANCE, Battery Installa- tion and Connection...
Page 689 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Battery terminal fastener 60-70 in-lbs 6.8-7.9 Nm 6.28 INTERACTIVE EXHAUST HARNESS: XB12 MODELS, Lightning Battery terminal fastener 60-70 in-lbs 6.8-7.9 Nm 6.28 INTERACTIVE EXHAUST HARNESS: XB12 MODELS, Ulysses Battery terminal fasteners 60-70 in-lbs 6.8-7.9 Nm...
Page 690 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Brake caliper bleeder valve 36-60 in-lbs 4-6.8 Nm 2.9 FRONT BRAKE: EIGHT PISTON CAL- IPER, Front Brake Fluid Line Brake hand lever fastener, Firebolt 80-90 in-lbs 9-10.2 Nm 2.31 HANDLEBARS: FIREBOLT, Installation...
Page 691 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Brake reservoir clamp fasteners, front 80-90 in-lbs 9.0-10.2 Nm 2.9 FRONT BRAKE: EIGHT PISTON CAL- IPER, Master Cylinder/Reservoir: Installation Brake reservoir cover fasteners, front 9-13 in-lbs 1-1.5 Nm 2.9 FRONT BRAKE: EIGHT PISTON CAL-...
Page 692 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Center tie bar 30-33 ft-lbs 40.7-44.7 Nm 3.4 ENGINE ROTATION FOR SERVICE, Assembly Center tie bar mount to engine fasteners 30-33 ft-lbs 40.7-44.7 Nm 3.6 ENGINE INSTALLATION, Assembly Chin fairing fasteners 36-48 in-lbs 4-5.4 Nm...
Page 693 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Cylinder studs 10-20 ft-lbs 13.6-27.1 Nm 3.18 CRANKCASE, Assembly/Special method required to tighten Damper rod jamnut 22-30 ft-lbs 29.8-40.7 Nm 2.16 FRONT FORKS, Assembly Deflector fasteners 24-36 in-lbs 2.7-4 Nm 2.28 DEFLECTORS, Assembly and Installation...
Page 694 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Fork clamp, lower 20-22 ft-lbs 27.1-29.8 Nm 2.17 FORK CLAMPS, Installation: Light- ning/Ulysses/LOCTITE 271 (red) Fork clamp, upper 23-25 ft-lbs 31.2-33.9 Nm 2.17 FORK CLAMPS, Installation: Firebolt/LOC- TITE 271 (red)
Page 695 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Front tie bar to V bracket 25-27 ft-lbs 33.9-36.6 Nm 2.25 CLUTCH CONTROL, Assembly and Installa- tion Front trunk pan fastener 72-96 in-lbs 8-11 Nm 2.49 AIR SCOOPS, Ram Air Scoop and Fan...
Page 696 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Heel guard fasteners, passenger, Fire- 72-96 in-lbs 8-10.8 Nm 2.34 FOOTPEG, HEEL GUARD AND MOUNT: bolt and Lightning FIREBOLT AND LIGHTNING MODELS, Passenger Heel guard fasteners, rider, Firebolt and 72-96 in-lbs 8-10.8 Nm...
Page 697 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Intake flange screws 96-120 in-lbs 10.8-13.6 Nm 4.15 THROTTLE BODY, Installation Interactive exhaust actuator fasteners 36-40 in-lbs 4-4.5 Nm 4.3 AIR CLEANER ASSEMBLY, Installation Left front trunk pan fastener, Lightning 72-96 in-lbs 8-10.8 Nm...
Page 698 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Mirror fasteners, Firebolt 72-96 in-lbs 8-10.8 Nm 2.47 FRONT FAIRING, WINDSHIELD, AND MIR- RORS: FIREBOLT, Installation Mirror mount onto bracket 20-22 ft-lbs 27.1-29.8 Nm 2.33 MIRRORS, Installation Muffler mount fastener, front -19-21 ft-lbs 25.8-28.5 Nm...
Page 699 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Oxygen sensor 40-45 ft-lbs 54.2-61 Nm 4.7 OXYGEN SENSORS (O2), Installation/ANTI- SEIZE Passenger grab handle, front fasteners 108-120 in-lbs 12.2-13.6 Nm 2.53 TRIPLE TAIL: ULYSSES MODELS, Installa- tion Passenger grab handle, rear fasteners 23-25 ft-lbs 31.2-33.9 Nm...
Page 700 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Rear brake line bracket fasteners 48-72 in-lbs 5.4-8 Nm 2.35 HEEL GUARD AND FOOTPEG MOUNTS: ULYSSES MODELS, Mount Installation Rear brake reservoir fastener 48-72 in-lbs 5.4-8 Nm 2.12 REAR BRAKE MASTER CYLINDER, Installa-...
Page 701 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Reed valve stop fastener 5-7 in-lbs 0.6-0.8 Nm 3.15 CRANKCASE BREATHING SYSTEM, Reed Valve Replacement/LOCTITE 222 (purple) Reservoir clamp fastener 120-144 in-lbs 13.6-16.3 Nm 2.23 REAR SHOCK ABSORBER, Installation: Firebolt...
Page 702 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Shock reservoir retainer fastener 80-88 in-lbs 9-10 Nm 2.49 AIR SCOOPS, Ram Air Scoop and Fan Shroud: Ulysses Side case brackets 108-120 in-lbs 12.2-13.6 Nm 2.54 LUGGAGE: XB12XT, Installation: Side Case...
Page 703 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Swingarm pivot shaft 44-46 ft-lbs 59.7-62.4 Nm 2.19 SWINGARM AND BRACE, Installation: Swingarm/ANTI-SEIZE Swingarm pivot shaft 44-46 ft-lbs 59.7-62.4 Nm 3.6 ENGINE INSTALLATION, Assembly/ANTI- SEIZE Swingarm pivot shaft pinch bolt 17-19 ft-lbs 23-25.8 Nm...
Page 704 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Trunk pan to center tail section, Lightning 48-72 in-lbs 5.4-8 Nm 2.40 LEFT TAIL SECTION AND BATTERY PAN: LIGHTNING MODELS, Assembly Trunk pan to center tail section, Lightning 48-72 in-lbs 5.4-8 Nm...
Page 705 2010 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Windshield mounting screw 25-30 in-lbs 2.8-3.4 Nm 2.48 WINDSHIELD AND WINDSCREEN: LIGHT- NING AND ULYSSES MODELS, Ulysses XB12XT/XB12XP Wire cover front fasteners 36-48 in-lbs 4.1-5.4 Nm 6.19 LICENSE PLATE LAMP ASSEMBLY, Ulysses...
Page 706 NOTES XXVI TORQUE VALUES...
Page 707 Cleaning and Inspection..... . 1-40 Tender........1-42 150 Metri-Pack Connector Voltmeter Test.
Page 708 Clutch Cylinder Head....... . . 3-35 Adjusting Screw Disassembly/Assembly..5-13 Assembly.
Page 709 Footpeg Mount (Rider) Gasoline Blends: Buell Models....1-7 Installation (Firebolt/Lightning)....2-133 Fuel Cap Retaining Ring Removal (Firebolt/Lightning).
Page 710 Installation....... . 4-22 Removal........6-35 Removal.
Page 711 Metri-Pack Terminals Crimping........A-19 Jets, Piston........3-84 Mirrors Installation.
Page 712 Removal........5-17 Gears........1-5 Tension (table).
Page 713 Side Case Assembly/XB12XT Subframe Tail Assembly Installation....... 2-182 Assembly (Firebolt)......2-144 Removal.
Page 714 Buell........i-II...

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